Experimental analysis and modeling of orthogonal cutting using material and friction models

In this study, a process model for orthogonal cutting processes is proposed. The model involves the primary and secondary deformation zones. The primary shear zone is modeled by a Johnson-Cook constitutive relationship and a shear plane having constant thickness. The secondary deformation zone is modeled semi-analytically, where the coefficient of friction is calibrated experimentally. The cutting forces predicted using the calibrated sliding friction coefficients are in good agreement with the measurements. The experimental investigation of sliding friction coefficients also show promising results for the proposed model, which is still under development.