The accuracy of a machining model depends on the capability of this model to describe the physical phenomena associated to the real machining system. This includes the material constitutive model and the approach used to describe the field flow of the material in cutting. In this paper, a model of high speed machining (HSM) of Ti6Al4V titanium alloy is developed. This cutting model includes the proposed constitutive model considering the influence of strain hardening, strain-rate, temperature, and state of stress (e.g., stress triaxiality and Lode parameter) in the material plasticity and damage. Finite Element Method (FEM) using Coupled Eulerian-Lagrangian (CEL) approach is used to simulate the cutting model. A sensitivity analysis of the influence of the mesh topography on the chip geometry and cutting force is performed resulting in the determination of the optimal element size and element orientation. Simulation results obtained using the CEL approach are compared with those obtained using the Lagrangian one. Moreover, simulated cutting force and chip geometry obtained using the proposed constitutive model are compared with those obtained using the Johnson-Cook (J-C) model, and experimental data. Both chip geometry and cutting force predicted by the proposed constitutive model is closer to the experimental one than the J-C constitutive model. The CEL approach combined with the proposed constitutive model can simulate material side flow, which results in a larger width of chip compared to the width of cut, and in the formation of lateral burr on the workpiece. It also permits simulating the cyclic variation of the plastic strain and topography of the machined surface along the cutting direction, observed experimentally.

加工模型的准确性取决于该模型描述与实际加工系统相关的物理现象的能力。这包括材料本构模型和用于描述切削中材料的场流的方法。本文建立了Ti6Al4V钛合金的高速加工（HSM）模型。该切削模型包括建议的本构模型，该模型考虑了应变硬化，应变速率，温度以及应力状态（例如，应力三轴性和Lode参数）对材料可塑性和损伤的影响。使用耦合欧拉-拉格朗日（CEL）方法的有限元方法（FEM）来模拟切削模型。对网孔形貌对切屑几何形状和切削力的影响进行了敏感性分析，从而确定了最佳的元件尺寸和元件方向。将使用CEL方法获得的仿真结果与使用拉格朗日方法获得的仿真结果进行比较。此外，将使用建议的本构模型获得的模拟切削力和切屑几何形状与使用Johnson-Cook（JC）模型获得的模拟切削力和切屑几何形状进行了比较，并提供了实验数据。所提出的本构模型预测的切屑几何形状和切削力均比JC本构模型更接近于实验模型。CEL方法与所提出的本构模型相结合，可以模拟材料的侧向流动，与切屑的宽度相比，切屑的宽度更大，并在工件上形成横向毛刺。还可以模拟沿实验方向观察到的塑性应变和加工表面形貌沿切削方向的周期性变化。