The influence of plastic properties on chip formation

A two-dimensional finite-element model of the chip formation process is used to study the influence of the material law determining plastic flow on chip formation of titanium alloys at high cutting speeds. For simplicity, friction and thermo-mechanical properties of the tool are neglected in the simulations. Titanium chips are strongly segmented and therefore especially suitable to study the role of segmentation for the cutting force and other cutting parameters. Of special interest is the influence of the thermal softening parameter in the material law. Increasing thermal softening leads to a drastic decrease in the cutting force and a corresponding increase in chip segmentation. A variation of the hardening exponent is also performed. It is shown that the simulation results can be understood by using adiabatic flow stress curves. The variation of the hardening exponent leads to strongly differing chip shapes, although the cutting force stays nearly constant. This shows that mean cutting forces should not be used as simulation verification parameters.