Effects of coefficient of friction coupled with a deformation dependent friction model in cutting simulations

A deformation dependent stick-slip based friction model is realised to better represent the contact stresses in the secondary shear zone. The instantaneous nodal limiting shear stress is implemented in a VFRIC friction model subroutine in ABAQUS\Explicit in 2D ALE orthogonal cutting simulations to investigate effects on the accuracy of the simulations. This study highlights that the limiting shear stress varies along the rake face, as well as with the rake angle and uncut chip thickness. Lower coefficients of friction are necessary at lower rake angles and higher uncut chip thicknesses, although a variable coefficient of friction model is still necessary to predict both the cutting force and thrust force accurately together.