A numerical model for tool–chip friction in intermittent orthogonal machining

This article presents a novel model to study the influence of surface textured cutting tools in near-micromachining conditions. The model utilizes the Challen and Oxley’s asperity deformation model (Van Luttervelt et al., CIRP Ann Manuf Technol, 1998, vol. 47, pp. 587–626; Arrazola et al., CIRP Ann Manuf Technol, 2013, vol. 62, pp. 695–718) paired with an approach to a priori estimate of the interfacial film formation at the tool–chip interface. The procedure considers the chemical effect of the environment, along with the mechanical aspects of the surface texture of the cutting tool’s rake surface. Model performance, in terms of predicting machining forces and coefficient of friction, was validated with existing experimental data (Anand et al., Proceedings of the international conference on advancements and futuristic trends in mechanical and materials engineering, 5–7 October 2012, pp. 661–666). The outcome trend of the proposed model approximately matches with the experimental results. Further, the model tries to explain the impact of cutting tool’s surface roughness on overall tool–chip friction while performing intermittent cutting in the near-micromachining regime.