Development and validation of a new friction model for cutting processes

The friction model in the tool-chip interface has significant influences on predicting chip forms, cutting forces, and cutting tool temperatures, when simulating the chip formation using the finite element method. In this paper, the friction behavior in the tool-chip interface was investigated experimentally and numerically under cutting conditions. The friction tests were performed with different workpiece materials (AISI 1045 and Direct Aged Inconel 718) in combination with uncoated and coated cemented carbide cutting tools. Various process normal forces were applied to achieve different contact pressures. The experimental results showed strong influences of relative speeds, contact pressures, and contact temperatures on apparent friction coefficients. In addition, an advanced friction model was proposed and validated with 3D FE-simulations of the friction test.