A new damage evolution criterion for the coupled Eulerian-Lagrangian approach: Application to three-dimensional numerical simulation of segmented chip formation mechanisms in orthogonal cutting

A damage evolution law is proposed to consider the frictional behavior within an Eulerian material after full as a Lagrangian material, where mesh explicitly describes newly born interface interactions. This approach prominent for simulating severe plastic deformation (SPD) processes during which separation can occur. Among these, orthogonal cutting represents simplest process comparison with simulation because it offers accessibility measuring physical quantities in situ vicinity of tool. Therefore, numerical model based on coupled Eulerian-Lagrangian formulation simulate segmented chip formation mechanisms was developed. simple initiation criterion used, and coded ABAQUS subroutine VUSDFLD. The both continuous formation, depending experimental configuration, while satisfactorily predicting morphology such temperature, primary shear band forces. Additionally, non-negligible side flow observed experimentally successfully predicted by simulation. accuracy auspicious its subsequent extension three-dimensional SPD (i.e., milling, friction stir welding, etc.).