The Mechanics of Cutting: In-situ Measurement and Modelling

This work presents a new constitutive modelling approach to describe the operating friction mechanisms inmaterial cutting. The modelling approach is based on an advanced experimental set-up with high speed filming and thermography of the orthogonal cutting process as well as the Merchant's circle force diagram. Finite element cutting simulations on carbon steel AISI 1045 with different uncut chip thicknesses were conducted to validate the developed friction modelling approach. A realistic analytical and numerical prediction of chip formation, local thermo-mechanical load and cutting force could be achieved.