Development of new predictive analysis in the orthogonal metal cutting process by utilization of Oxley's machining theory

This paper presents a contribution to improving an analytical thermo-mechanical modeling of Oxley&#39;s machining theory of orthogonal metals cutting, which objective is the prediction of the cutting forces, the average stresses, temperatures and the geometric quantities in primary and secondary shear zones. These parameters will then be injected into the developed model of Karas <i>et al</i>. (2013) to predict temperature distributions at the tool-chip-workpiece interface. The amendment to Oxley&#39;s modified model is the reduction of the estimation of time-related variables cutting process such as cutting forces, temperatures in primary and secondary shear zones and geometric variables by the introduction the constitutive equation of Johnson-Cook model. The model-modified validation is performed by comparing some experimental results with the predictions for machining of 0.38% carbon steel.