A numerical modeling method for plane strain orthogonal cutting in steady state is developed on the basis of the rigid-plastic finite element method. The methods for determining the material and frictional properties to be used in the model are discussed. The shape of chip, i.e., the thickness and curl, distributions of stress and strain are calculated. Fracture of chip is predicted by combining the present model with the criteria of ductile fracture. The simulated results agree well with the results obtained by the microscale cutting experiment carried out within a scanning electron microscope.

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