On friction modeling in orthogonal machining: An Arbitrary Lagrangian-Eulerian finite element model

This work presents a finite element study using the Arbitrary Lagrangian-Eulerian (ALE) approach to investigate friction behavior along the chip tool interface during orthogonal cutting. The main focus was to examine how a limiting shear stress on a basic Coulomb friction model would influence the nature of chip tool interface. It was found that the choice of the limiting shear stress value alters the ratio between the sticking and sliding length along the chip tool interface while has small effect on the predicted chip thickness. Analyzing the stresses, strains and temperatures generated contributes to a better understanding of what is physically happening at the chip tool interface. Varying the limiting shear stress at the interface helps in understanding how the material is behaving at the interface and contributes to the ongoing discussion about what value of limiting shear stress is appropriate.