In this work, a two-dimensional finite element model of orthogonal machining ofAISI 1045 steel is developed using the commercial non-linear finite element packageABAQUS. The material behavior is described using the Johnson-Cook constitutivelaw. Furthermore, the Johnson-Cook damage model for damage initiation and Hillerborg’s model with fracture toughness values are used for damage evolution. Thefracture-based approach outlined by Patel and Cherukuri in a previous work is usedfor chip separation and serration. The friction conditions between the cutting tooland chip are captured using a stress-based criterion.The predictions from the model are validated by comparing with the experimentalresults available in the literature for 1045 steel. Once validated, various parametric studies are conducted to study the process parameter effect on cutting forcesand tool-chip interfaces. The results from the parametric studies are compared withexperimental results to further validate the fracture-based approach for cutting simulations. In addition, since multiple sets of values for the Johnson-Cook parametersare quoted in the literature for 1045 steel, the effect of these different sets on cuttingforces is also studied.It is found that the model is capable of predicting accurate cutting forces andtool-chip interface temperatures. However, it does not predict the chip shapes accurately. Further refinement of the fracture models using a combined experimental andtheoretical work is needed to improve on the chip shape predictions.
