Influence of friction models on FE simulation results of orthogonal cutting process

It is well-known that the reliability of finite element (FE) simulation results of cutting processes depends mainly on two factors: implementation of a well-defined constitutive model which can properly represent the severe deformation in chip formation process as well as the viability of the relation adopted to simulate the frictional condition at the tool-chip interface. In the current study, a systematic approach is presented to evaluate the performance of various friction models in three different FE commercial codes: Deform 2D, Abaqus/Explicit and AdvantEdge. The frictional condition was analysed for two uncoated cemented carbide-plain carbon steel combinations: K10/AISI 1045 and H13A/AISI 1080. The results indicated that approximately similar ranges of minimum average error in simulation responses can be achieved, independently of the FE code used for simulation of the chip formation process and for both tool-work material combinations. The reasons for this observation were critically discussed.