Abstract
A thermo-elasto-viscoplastic two-dimensional finite element analysis of the effects of different edge radii on the mechanics of orthogonal metal cutting is presented. The shear stress distribution was used to quantify the stagnation point as well as the minimum chip thickness needed to form a chip when using a honed cutting edge. The determined location of the stagnation point using the shear stress distribution agrees well with location calculated using the velocity profile in the vicinity of the cutting edge. The plastic flow of the material around the honed cutting edge and below the machined surface was studied. The ploughing force generated while cutting with a carbide tool was calculated. Contour plots of stress, strain, temperature, and velocity in the cutting zone were analysed along with contact stresses and temperature profiles on the rake face.