Validation of Material Models for Machining Simulation Using Mechanical Properties of the Deformed Chip

Finite element simulation of machining is increasingly popular in both industry and academia. Simulation accuracy is, in part, critically dependent on identification of the appropriate material constitutive laws. Calibration and validation of the laws is typically limited to using uniaxial flow stress data and/or machining outputs such as forces, temperatures, and chip morphology features. The spatial distribution of material state (i.e. microstructure, mechanical properties, residual stresses) of the machined chip, which encodes path-dependent process information, is seldom utilized for model validation. In this paper we explore a complimentary validation technique that compares model predictions against measured spherical nanoindentation stress-strain curves.