Abstract: A coupled thermo-mechanical, plane-strain model is used to simulate the process of orthogonal machining high-strength wear-resisting aluminium bronze with continuous chip formation. The cutting process is simulated from the initial to the steady state of the cutting force and temperature by incrementally advanced the cutting tool and the function of remeshing in the software Marc. The shape of the chip and the temperature, stress, strain and strain-rate fields have been obtained for a range of cut depths and cutting velocities. The calculated cutting forces and the temperatures are well agreed with the experimental data.

Key words: Chip formation, Cutting, Finite element method, Thermo-mechanical coupling