We did 2 projects of simulating machining processes to find chip shape, chip thickness, energy dissipation and effect of tool shape on the above matters using jhonson cook's model for steel and aluminum at Fracture Mechanics and Fatigue Lab. UET Taxila Pakistan. I'll be happy if we could be of any help. 

yes..

Sir what are the essential prerequisites for turning simulation through ABAQUS...

The pre requisites are :

1. Geometry (tool and WP)

2. material model (Elasticity, density, thermal conductivity, specific heat capacity, Johnson cook plasticity, Johnson cook damage, damping, thermal expansion)

3. Interaction or contact between tool and WP (Rake with chip, Flank with newly machined WP surface, Rake with side of WP for first instance of contact)

4. Interaction property should include: friction, normal behavior and heat conductance

5. BC to fix WP and determine tool velocity (cutting speed)

6. Simulation step: temp-displacement explicit

7. Mesh

8. That's it and submit

Hi Suresh & Mohamed

I hope you are doing well. actually I did 3D simulation in machining successfully,however, in 2D simulation, I am not able to finish the job because of mesh distortion. My main problem right now is thermal analysis in machining. I used dynamic coupled tem-dis with coupled-temp-disp mesh type, I input thermal properties of both tool and workpiece, but it has huge mesh distortion. could you please help me, is there anything i missed? how about heat transfer? Should i define anything related to that? where? If you can help me that would be appreciated, cause i have been struggling with this problem for a while.

Regards

Ardalan