Benefited from the recent development of the high-performance computer and software for finite element analysis

numerical modelling has become one of the efficient tools to help understand cutting mechanism

study tool wear and improve surface quality during machining process. Commonly used material constitutive models are summarized

and analyze several key factors encountered when establishing the cutting simulation model. A systemic introduction of the recent research development involved in chip formation

cutting temperature

cutting forces

tool wear

tool design and residual stress prediction as well as microstructure evolution simulation was addressed. Finally

toward the existing challenges in cutting simulation modeling

the future scope and hot issues needing further study in this field were outlined.