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ELSEVIER Journal of Materials ProcessingTechnology 70 (1997) 22-33 Three-dimensional cutting process analysis with different cutting velocities Zone-Ching Lin *, Yuung-Der Yarng Deparrmenr of hldumicai Engineering, Narional Taiwan Lstilure of Techdog): 43 Krelurrg Road, Srcrion 4. Tmpri 10772. Tuiwm. ROC Received16 January 1996 This paper uses the large deformation large strain finite-element theory, the updated Lagrangian formulation and the incremental theory approach to develop a 3D elastic-plastic analytical model that examines metal cutting on the tool tip and twin nodes on the machined face. The geometric position and the critical value of strain energy density, combined with twin node treatment, are also introduced to serve as the continuous chip separation criterion. Finally, the 3D low-velocity cutting condition of mild steel was explored to analyze changes in the appearances of the workpiece and the chip, the distribution of stress and strain, and the progress of changes in the cutting force. The impact of different cutting velocities and the initial conditions of the residual stress were studied to understand the impact of various cutting conditions on the machined workpiece. The numerical average cutting forces are compared with the experimental cutting forces with the different low-cutting velocities to verify that the 3D cutting model that has been developed is reasonable. 0 1997 Elsevier Science S.A. Keywd.s: Cutting; Elastic-plastic: Three-dim