Friction and Material Modelling in Finite Element Simulation of Orthogonal Cutting

In the present paper the influence of the friction and material modelling on the results of the Finite Element simulations of machining is investigated. An orthogonal cutting model is proposed, which incorporates Coulomb’s friction law. The validity of this model is tested against similar experimental and numerical results from the relevant literature and the influence of the friction coefficient is investigated. Then, a second model, with a friction model based on Zorev’s stick-slip theory, is prepared and compared to the first one. Furthermore, simulations with Johnson-Cook material model for both kinds of friction modelling are presented and compared to the other models. The results of the different kinds of models although exhibit small discrepancies between models’ results such us cutting forces, affect temperatures and chip morphology.