Overview of advances in numerical cutting: Theoretical methods and predictive indicators

Numerical simulation is a crucial technical approach in the research of high-performance machining. It effectively guides the selection of process parameters, cutting tools, and cooling/lubrication methods, while enabling the prediction of both geometric and physical information during the cutting process. In recent years, significant progress has been achieved in numerical studies of cutting processes oriented towards industrial application requirements. Based on recent advancements in modeling and simulation methods, material constitutive behaviors, and friction characterizations, this paper summarizes the research progress of numerical cutting simulation in predicting fundamental physical information and performance indicators for industrial needs. Furthermore, addressing the gap between current research and practical industrial demands along with the challenges faced, several development directions for future research are proposed. This work aims to lay a foundation for the further advancement of digitalized and high-performance machining.