Simulation of material side flow using a 3D coupled Eulerian-Lagrangian approach and a constitutive model considering the stress state

New advance in modelling of the machining process is of great significance to improve component performance and manufacturing efficiency. This includes the material constitutive model and the approach used to describe the field flow of the material in cutting. In this study, a 3D model of high speed machining (HSM) of Ti6Al4V titanium alloy is developed. The coupled Eulerian-Lagrangian (CEL) approach was used to simulate the proposed cutting model. This cutting model includes a proposed constitutive model considering the strain hardening, strain-rate, temperature and stress state (e.g., stress triaxiality and Lode parameter) in the material plasticity and damage. This machining model is able to simulate the phenomenon of material side flow, which results in a larger chip width when compared to the width of cut and the lateral burr formation. The phenomenon of material side flow is validated by experimental results. The distribution of plastic strain and stress state shows that the workpiece transforms from plane strain state in middle surface to plane stress state in lateral surface, which finally results in the formation of lateral burr.