Finite element analysis of the orthogonal metal cutting process

In this paper, the orthogonal metal cutting process is analyzed with the finite element method under plane strain conditions. Frictional interaction along the tool–chip interface is modeled with a modified Coulomb friction law, and chip separation is based on a critical stress criterion and is simulated using a nodal release procedure. Finite element solutions of temperature, stress, strain, and strain rate fields have been obtained for a range of tool rake angle and friction coefficient values. Results showing how the tool–chip interfacial friction affects the field distributions are new and add to the existing knowledge base. This paper also reports the procedure and specific modeling techniques for simulating the orthogonal metal cutting process using a general-purpose finite element computer code. The findings of this paper provide useful insights for understanding and for improving the orthogonal metal cutting process.