A new analytical tool-chip friction model in dry cutting

To be much closer to the cutting process and the actual cutting phenomenon, a new tool-chip friction model proposed in this paper takes account of the thickness of the material transfer layer of the chip which is ignored by most existing friction models. The material transfer layer, in which the chip material nearly stagnates on the tool rake face during machining, is located between the tool-chip contacting interface and the cutting interface in the secondary shear zone. Furthermore, the proposed model also contains the sticking, the transition, and the sliding friction regions along the tool-chip contacting surface and comprehensively depicts every region’s physical performance during dry machining. The global and the local friction characteristics between the tool and the chip are described based on coupled thermomechanical analytical method. Numerical results solved by the proposed model are compared with the existing experimental and simulated data in available literature. The results show that the proposed model was in good agreement with the experiments. The model provides an analytical method to predict friction characteristics conveniently and efficiently on the tool rake face during dry machining.