Abstract
This paper presents a two‐dimensional finite element model of orthogonal cutting. The proposed model has been developed with Abaqus/explicit software. An Arbitrary Lagrangian‐Eulerian (ALE) formulation is used to predict chip formation, temperature, chip‐tool contact length, chip thickness, and cutting forces. This numerical model of orthogonal cutting will be validated by comparing these process variables to experimental and numerical results obtained by Filice et al. [1]. This model can be considered to be reliable enough to make qualitative analysis of entry parameters related to cutting process and frictional models. A sensitivity analysis is conducted on the main entry parameters (coefficients of the Johnson‐Cook law, and contact parameters) with the finite element model. This analysis is performed with two levels for each factor. The sensitivity analysis realised with the numerical model on the entry parameters has allowed the identification of significant parameters and the margin identification of parameters.
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