An investigation of sticking behavior on the chip–tool interface using thermo-elastic–plastic finite element method

This paper presents a high-speed orthogonal cutting model and also establishes a finite element method to analyze the mechanics of steady state in the high-speed orthogonal precision cutting process of oxygen-free high conductivity copper. The paper proposes a variant pseudo-friction coefficient concept to modify the large-deformation finite element formulation and to develop a stress analysis model of the chip–tool interface to solve the problems of the shear stress, normal stress and variant pseudo-friction coefficient on the chip–tool interface. In spite of the high-speed micro-cutting, the effect of high strain rate and high temperature will produce the sticking phenomenon on the rake face of the tool. Not only will the sticking phenomenon shorten tool life, but also will have an effect on the machining accuracy in precision diamond cutting. Therefore, the results in this study can be considered as acceptable consideration during the procedure of high-speed precision cutting.