Developments in modelling of metal cutting processes

Following a brief historical perspective on the development of orthogonal cutting model's, including key work by Merchant and Oxley, the paper concentrates on the use of finite element techniques to simulate two-dimensional orthogonal turning and the subsequent transition to three-dimensional formulations, thus enabling milling and drilling to be realistically modelled. Input requirements including material models, mechanical property data at elevated strain rates and temperatures, contact conditions, and other boundary conditions needed to ensure accurate simulation and predictions are discussed. Current academic research and commercial developments involving simulation of non-conventional processes, microscale cutting, workpiece surface integrity, and microstructure modelling, etc., are also highlighted.