In this paper, a coupled model of the thermo-elastic-plastic material under large deformation for orthogonal cutting is constructed. A chip separation criterion based on the critical value of the strain energy density is introduced into the analytical model. A scheme of twin node processing and a concept of loading/unloading are also presented for chip formation. The flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in metal cutting. The cutting tool is incrementally advanced forward from an incipient stage of tool-workpiece engagement to a steady state of chip formation. The finite difference method is adopted to determine the temperature distribution within the chip and tool, and a finite element method, which is based on the thermo-elastic-plastic large deformation model, is used to simulate the entire metal cutting process. Finally, the chip geometry, residual stresses in the machined surface, temperature distributions within the chip and tool, and tool forces are obtained by simulation. The calculated cutting forces agree quite well with the experimental results. It has also been verified that the chip separation criterion value based on the strain energy density is a material constant and is independent of uncut chip thickness.

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