Cutting force prediction in micro orthogonal cutting by an analytical-numerical coupled model

The slip-line field model developed by Waldorf [1] for the macroscale is suitable to predict cutting forces when a large ploughing action occurs, as in micromachining, since it takes into account a rounded-edge tool. The present study considers the procedure that was developed in a past work of the same authors [2] to adjust the slip-line model for a specific target material by means of a restricted set of experiments. The aim of this paper is to improve this procedure by coupling analytical and numerical modeling and to make the calibration phase independent from cutting experiments. The prediction performance of the analytical-numerical coupled model is evaluated by an objective comparison between the predicted cutting and thrust forces and the forces acquired in the experimental campaign carried out on C38500 brass (CuZn39Pb3).