Int. J. Machining and Machinability of Materials, Vol. 14, No. 3, 2013 213 Copyright © 2013 Inderscience Enterprises Ltd. Finite element simulation of effect of residual stresses during orthogonal machining using ALE approach P. Krishnakumar* Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amrita Nagar, Coimbatore-641 112, Tamilnadu, India Fax: +91-422-2656274 E-mail: p_kkumar@cb.amrita.edu *Corresponding author K. Prakash Marimuthu Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Bengaluru-560 035, Karnataka, India E-mail: prakash_muthu@rediffmail.com K. Rameshkumar and K.I. Ramachandran Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amrita Nagar, Coimbatore-641 112, Tamilnadu, India E-mail: k_rameshkumar@cb.amrita.edu E-mail: ki_ram@cb.amrita.edu Abstract: In this paper, a finite element model has been developed to predict the effect of residual stress induced in the work material during multiple pass turning of AISI 4340 steel. Chip morphology and force variation during machining are also quantified using the FE model. Finite element model was developed using arbitrary Lagrangian-Eulerian formulation along with Johnson-Cook material model and Johnson-Cook damage model. The finite element model developed in this study was validated experimentally by studying the chip morphologogy and cutting force variation during the machining. Results indicate that there is good correlation existing between numerical results and experimental results. Keywords: chip morphology; ALE formulation; residual stress; sequential cuts; multi-pass orthogonal machining.