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<p>In this paper, the constitutive parameters of the Johnson–Cook (J–C) model for hardened AISI D2 steel (62 HRC) are identified and evaluated for machining applications. The identification is based on stress–strain curves generated by JMatPro over a wide range of temperatures and strain rates, using only the material’s chemical composition and hardness as input data. The identified parameters are subsequently implemented in a two-dimensional finite element model of orthogonal cutting developed within an Arbitrary Lagrangian–Eulerian (ALE) formulation, which enables stable simulation of chip formation without mesh distortion or the need for a damage criterion. The numerical model is used to analyze cutting force, chip thickness, and tool–chip interaction characteristics under hard machining conditions. In parallel, a corrected analytical version derived from Oxley’s model is implemented using the same constitutive description, allowing a direct comparison between analytical predictions and ALE-based numerical results. The predicted cutting force and chip thickness are compared with available experimental results, showing good agreement. These results demonstrate that Johnson–Cook parameters identified from stress–strain data obtained from chemical composition and hardness can provide consistent and reliable predictions across different analytical and numerical machining models.</p>

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Determination of Johnson–Cook parameters and enhanced orthogonal cutting simulation of AISI D2 hard steel

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • Zoubir Aich,
  • Khaled Djellouli,
  • Islam Hachemi,
  • Abdelhamid Ghezal

摘要

In this paper, the constitutive parameters of the Johnson–Cook (J–C) model for hardened AISI D2 steel (62 HRC) are identified and evaluated for machining applications. The identification is based on stress–strain curves generated by JMatPro over a wide range of temperatures and strain rates, using only the material’s chemical composition and hardness as input data. The identified parameters are subsequently implemented in a two-dimensional finite element model of orthogonal cutting developed within an Arbitrary Lagrangian–Eulerian (ALE) formulation, which enables stable simulation of chip formation without mesh distortion or the need for a damage criterion. The numerical model is used to analyze cutting force, chip thickness, and tool–chip interaction characteristics under hard machining conditions. In parallel, a corrected analytical version derived from Oxley’s model is implemented using the same constitutive description, allowing a direct comparison between analytical predictions and ALE-based numerical results. The predicted cutting force and chip thickness are compared with available experimental results, showing good agreement. These results demonstrate that Johnson–Cook parameters identified from stress–strain data obtained from chemical composition and hardness can provide consistent and reliable predictions across different analytical and numerical machining models.