The chip formation in metal cutting which is not easily observable and measurable during machining is modeled by means of the finite element method (FEM). The reciprocal interaction between mechanical and thermal loads is taken into consideration by involving the thermo-viscoplastic flow behavior of workpiece material. Local and temporal distributions of stress and temperature in the cutting zone are calculated depending on the cutting parameters. The calculated cutting forces and temperatures are compared with the experimental results. The model can be applied in process design for selecting appropriate tool-workpiece combination and optimum cutting conditions in terms of mechanical and thermal loads.
