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