A physically based constitutive model for simulation of segmented chip formation in orthogonal cutting of commercially pure titanium

The accuracy of cutting simulations depends on the knowledge of micro-scale physics included in the constitutive and microstructure evolution models of the cutting process. This paper presents an enhanced physically based material model that accounts for microstructure evolution induced flow softening due to the inverse Hall-Petch effect below a critical grain size. The model's ability to simulate segmented chip formation and grain refinement in the shear bands produced in orthogonal cutting of commercially pure titanium is evaluated through finite element simulations and experiments. Results show good prediction accuracy for the cutting and thrust forces, chip morphology, and segmentation frequency.