A crystal plasticity-based model for oblique cutting of face-centered cubic single crystals

In this work, an analytical oblique cutting model has been proposed. This model is building on a one-dimensional approach for which the chip is formed by shearing within the primary shear zone. The impact of the material anisotropy is considered through a crystal plasticity-based constitutive model. The cutting forces and the corresponding specific energies are estimated using the physical-based normal shear angles procedure and Merchant’s normal shear angle procedure. The model is validated using the experimental data obtained from the literature. According to the results, the numerical and experimental findings are in good agreement. The model is then used to evaluate the impact of the crystallographic orientations and the machining parameters during oblique turning. The results show that the impact of the machining parameters on the cutting forces is correctly depicted. It is also demonstrated that whatever the crystal orientations are, the signature of cutting forces during oblique turning shows a fourfold symmetry. In addition, the variation of the cutting forces according to the rotation angle follows the evolution of the associated cumulative shear strain required to accommodate the plastic deformation. Finally, the simulations demonstrate that the chip flow angle, which has a significant effect on chip control, is greatly affected by the orientation of the single crystal.