Modelling and simulation of machining processes

The modelling of metal cutting has proved to be particularly complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/friction and material failure. The present work outlines the wide range of complex physical phenomena involved in the chip formation in a descriptive manner. In order to improve and understand the process different numerical strategies have been used for simulation. Several of these numerical strategies are reviewed and a short discussion of their relative merits and drawbacks is presented. By means of several examples, where a combined experimental/numerical effort was undertaken, we try to illustrate what numerical techniques, models and pertinent parameters are needed for successful simulations.