Metal cutting process is used to remove unwanted material (chip) and achieve desired surface shape and accuracy of engineering components. The process of the chip formation is the important for the metal cutting. Many investigators have contributed to theoretical analyses and experimental measurement on metal cutting process [1～3]. But the numerical simulation of the chip formation is few. In this paper, the mechanical cutting process of metal is simulated by thermo-mechanical coupled method. At first, the key technologies of simulating cutting process are discussed. The geometric criterion model modeling approaches has been used for the continuous separation of the work piece to form a chip. The contact and friction between work piece and cutter are analyzed. Secondly, the effect of the cutting speed on the chip formation is studied. At last, the FEM analysis gives the temperature, stress strain distribution of the chip and cutter. The FEM results show that the chip formation is different because of the different cutting speed. The model exhibits the transition from continuous to segmented chips with increasing cutting speed. The cutting temperature of the chip is higher as the cutting speed increases.
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