This article begins with information on the fundamentals of chip formation process and general considerations for the modeling and simulation of machining processes. It focuses on smaller-scale models that seek to characterize the workpiece/tool/chip interface and behaviors closely associated with that. The article describes the advantages and disadvantages of various finite-element modeling approaches, namely, transient models, continuous cutting model, steady-state model, hybrid model, two-dimensional models, and three-dimensional models. It discusses flow stress measurements using constitutive and inverse testing methods and reviews tool design for chip removal. The article explains the effect of tool geometry on burr formation and the effect of coatings on tool temperatures. It concludes with information on tool wear, which is an unavoidable effect of metal cutting.

This article describes the most commonly used test methods for determining flow stress in metal-forming processes. The methods include tension, ring, uniform compression, plane-strain compression, torsion, split-Hopkinson bar, and indentation tests. The article discusses the effect of deformation heating on flow stress. It provides metallurgical considerations at hot working temperatures and presents flow curves at conventional metalworking strain rates. The article describes the effect of microstructural scale, crystallographic texture, and equiaxed phases on flow stress at hot working temperatures. It tabulates a summary of certain values describing the flow stress-strain rate relation for steels, aluminum alloys, copper alloys, titanium alloys, and other metals at various temperatures.

Computer simulation of microstructural evolution during hot rolling of steels is a major topic of research and development in academia and industry. This article describes the methodology and procedures commonly employed to develop microstructural evolution models to simulate microstructural evolution in steels. It presents an example of the integration of finite element modeling and microstructural evolution models for the simulation of metal flow and microstructural evolution in a hot rolling process.

This article discusses the equipment design, procedures, experimental considerations, and interpretation of the torsion tests used to establish workability. It describes the application of torsion testing to obtain flow-stress data and to gage fracture-controlled workability and flow-localization-controlled failure. The article discusses the torsion test used to establish the processing parameters that are required to produce the desired microstructures.

This article introduces the reasons behind the selection of a deformation process as the method of choice for producing a part or product form. It discusses the advantages, disadvantages, and categories of deformation processes. The article describes the major design considerations in applying a deformation process. Some fundamental aspects of plastic flow, flow stress, cold and hot working, workability, and formability are presented. The article provides information on free-surface cracking, central burst or chevron cracking, and cracking on die contact surface, as well as the microstructural effects on metal flow. It also discusses the defects in sheet-metal formed parts and flow-related defects in bulk forming.