It is well known that the chip morphology predictions in machining simulations depend on the separation criteria used for modeling chip formation. In this paper, we propose to use two different criteria for chip separation and serration along with the Johnson-Cook damage model. The threshold value for chip separation is determined from machining experiments using the methodologies discussed in Patel et al. [1]. In addition, two separate damage evolution laws for chip separation and serration are used. Our results indicate that the choice of the evolution law and the threshold values of Gc used for chip separation and serration have a significant effect on chip shape and other field variables such as the equivalent plastic strain, cutting force, temperature, etc.

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