Due to chip-flow interference and coordination, the two types of chips formed in the processes of double-edged cutting make a remarkable difference to cutting force components, tool service life, and machined parts quality. However, the chip formation mechanisms of both types are poorly understood, and the existing constitutive models generally fail to capture the deformation characteristics of the workpiece material during double-edged cutting. To this end, a new combined constitutive model composed of plasticity and damage parts is presented and applied to the finite element (FE) model for double-edged cutting of AISI 1045. The plasticity part considers the impacts of strain, strain rate, and temperature on the flow stress of workpiece material. The damage part considers the effects of stress states on the equivalent plastic strain at damage initiation. Double-edged cutting simulations were carried out employing the combined constitutive model and the Johnson-Cook (JC) model, respectively. To validate the presented constitutive model, experiments for double-edged cutting of AISI 1045 were completed, and the predicted results were compared with experimental results. It is concluded that the presented constitutive model substantially enhances the predicting accuracy for chip morphologies and cutting force components compared to the JC model. In addition, the two types chip formation mechanisms in double-edged cutting are revealed through analyzing the chip generation in simulations and the chips collected from the experiments. The new combined constitutive model contributes to the simulation-based optimization of the tool/process parameters in double-edged cutting to reduce the cutting forces or produce the desired chip morphology.

由于切屑流干涉和协调，在双刃切削过程中形成的两种切屑对切削力分量、刀具使用寿命和加工零件质量有显着影响。然而，对这两种类型的切屑形成机制知之甚少，现有的本构模型通常无法捕捉到工件材料在双刃切削过程中的变形特征。为此，提出了一种由塑性和损伤部分组成的新组合本构模型，并将其应用于AISI 1045双刃切削的有限元（FE）模型。塑性部分考虑了应变、应变速率和温度的影响。对工件材料的流动应力。损伤部分考虑了应力状态对损伤开始时等效塑性应变的影响。分别采用组合本构模型和 Johnson-Cook (JC) 模型进行双刃切削模拟。为了验证所提出的本构模型，完成了AISI 1045的双刃切削实验，并将预测结果与实验结果进行了比较。得出的结论是，与 JC 模型相比，所提出的本构模型显着提高了对切屑形态和切削力分量的预测精度。此外，通过对仿真中的切屑产生和实验收集的切屑进行分析，揭示了双刃切削中两种类型的切屑形成机制。