Identification of a friction model for modelling of orthogonal cutting

Numerical approaches to high-speed machining are necessary to increase the productivity and to optimise the tool wear and the residual stresses. In order to apply such approaches, rheological behaviour of the antagonists and friction model of interfaces have to be correctly determined. The existing numerical approaches that are used with the current friction models do not lead to good correlations of the process variables, such as the cutting forces or the tool–chip contact length. This paper proposes a new approach for characterizing the friction behaviour at the tool–chip interface in the zone near the cutting edge. An experimental device is designed to simulate the friction behaviour at the tool–chip interface. During this upsetting-sliding test, an indenter rubs in a specimen with a constant speed, generating a residual friction track. Contact pressure and friction coefficient are determined from the test’s numerical model and are then used to identify the friction data according to the interface temperature and the sliding velocity. These initial findings can be further developed for implementation in FEA machining models in order to increase the productivity.