A new methodology is presented to evaluate material properties at high strain rates and high temperatures based on orthogonal metal cutting experiments and FEM simulations. Average strain rate and average temperature found in the deformation zone are computed and flow stress data at these conditions are modified until cutting forces calculated in simulations match those determined in experiments. Material properties obtained from this method were verified by additional metal cutting simulations. Deviation from cutting forces measured in experiments was less than 10%. The feasibility of tool design using FEM simulations is also demonstrated.
