An Eulerian finite element model is presented that simulates orthogonal metal cutting. The model predicts chip geometry and temperature distribution in the workpiece, chip, and tool without the need for empirical cutting data. With the capability to predict chip geometry, the tool-chip contact length can also be found. Characteristics of the flow field in the vicinity of the tool can also be determined, such as the material velocity, and the stress and strain-rate distributions. It was found that the shear stress occurs over a finite region in front of the tool, rather than a single shear plane. Cutting experiments were performed for aluminum alloy 6061-T6 to validate the model. Good correlation with the model was found based on tool forces and average tool-chip interface temperature measurements.

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