Abstract: Based on thermo-elastic-plastic finite element equation for simulating the metal orthogonal cutting process, a coupled thermo-mechanical model with regard to plain strain orthogonal metal cutting is constructed under some assumptions. In addition, several special finite element techniques, such as the chip separation criteria and friction model, have been implemented to improve the accuracy and efficiency of the finite element simulation. A chip separation criterion based on stress failure is adopted to realize the separation of twin nodes. In the end, the machining process of material AISI4340 is simulated, and some results of simulation are analyzed and discussed. This coupled thermo-mechanical model is proved to be right by comparing the simulated results with the experimental data.

Key words: cutting process, coupled thermo-mechanical, chip separation criterion, finite element simulation