A method for FE simulation of serrated chip formation during high speed machining hardened steel

A finite element method involving Johnson-Cook material model and fracture criterion was used to simulate the serrated chip morphology during high speed machining AISI 4340 hardened steel in different rake angles using commercial FE software ABAQUS. The effects of rake angle and chip morphology on cutting force were discussed. The investigation indicates that the simulation results are consistent with the experiments and this FE simulation method presented can be use to predict the chip morphology and cutting force accurately during high speed machining hardened steel.