Improving the friction model for the simulation of cutting processes

The here developed friction model for numerical simulations of machining processes takes account of the physical‐mechanical phenomena occurring in different cutting zones by determining the concentrated forces acting in these zones. The forces acting in the primary and tertiary zones were divided from the general cutting forces obtained by experiment or calculated analytically. The forces in the plastic and elastic contact of the secondary cutting zone were identified by eliminating the elastic contact due to a reduction in the rake face of the cutting wedge. For each respective zone, a coefficient of friction was determined as a quotient of normal and tangential forces. •The interaction of tool with chip and workpiece is represented by local forces.•Local forces acting in cutting zones are determined by splitting the total forces.•Procedure for decomposition of total forces into local cutting forces is developed.•The local friction coefficients were determined for AISI 1045 and AISI 4140 steels.