A Literature Review and Finite Element Analysis of Chip Formation in Metal Cutting Using Different Tools and Workpiece Materials

This paper presents a comprehensive literature review and finite element analysis (FEA) of chip formation in metal cutting using Abaqus, comparing soft high-speed steel (HSS) tools and hard tungsten-carbide (WC) tools across various workpiece materials. Soft HSS tools are analyzed for difficult-to-machine alloys, including cast iron, titanium alloys, high-carbon steel, and hardened steel, while hard WC tools are analyzed for soft non-ferrous metals, such as aluminium, copper, zinc, and lead. Key machining parameters—cutting speed, feed, cutting temperature, chip morphology, and lubrication type—are summarized. The study highlights the effects of tool hardness and workpiece material on chip formation, cutting-zone temperature, and tool life, providing guidance for literature-based FEA modeling and future experimental validation.