Metal Cutting Data Integration with Different Contact and Friction Conditions, Kinematics, Tool Geometry, and Temperatures

Abstract

The data integration with additional artificial intelligence (AI) creates a lot of interest in industry as well as in the scientific world. The aim is to determine the complete production result before processing. But before we develop the complicated mathematical algorithm for creating a relevant digital machining process, the true nature of the process must be understood. A systematic analysis of the existing metal machining process reveals several different problem areas with an interdependent relationship. There is a metal deformation process that depends on the existing material properties influenced by stress, strain rate, hydrostatic pressure, and temperature. This problem area will be mathematically described and result in adequate equations for the stress and strain-rate situation for developing the existing plastic deformation. The next problem area is determined by the physical relation of contact and friction around the tool. Why do built-up edge, built-up layer, and material flow blockade occur at the tool, and what are the consequences of all these phenomena on the cutting process? Furthermore, where does the dynamic process come from, accompanied by dynamic forces and resulting in different temperatures and discontinuous chip flow? All this will be discussed in this paper and presented with practical evidence.

Received: 21 August 2025 | Revised: 3 November 2025 | Accepted: 17 November 2025

Conflicts of Interest

The author declares that he has no conflicts of interest to this work.

Data Availability Statement

Data are available from the corresponding author upon reasonable request.

Author Contribution Statement

Wolfgang Lortz: Conceptualization, Methodology, Software, Validation, Formal analysis, Investigation, Resources, Data curation, Writing - original draft, Writing -  review & editing, Visualization, Supervision, Project administration.