Thermomechanical modeling and simulation analysis of orthogonal cutting

A new thermomechanical method is presented based on the unequal division shear zone model for orthogonal cutting. The material constitutive relationship in the primary shear zone was represented using Johnson-Cook equation. The governing equation of the velocity, strain, stress and temperature of chip flow through the primary shear zone were established. At the tool/chip interface, a chip speed-dependent friction law was introduced. While calculating the flow stress iteratively, the effects of working hardening and thermal softening on flow stress were considered. Finally, predictive cutting forces for different machining econditions were compared with orthogonal cutting test data from the available literature and found in reasonable agreement. The cutting forces can be predicted only by workpiece material properties and cutting conditions without any additional experimental data of orthogonal cutting in the model proposed.