The state of the art for numerical simulations of the effect of the microstructure and its evolution in the metal-cutting processes.

Microstructure features directly reflect mechanical responses during material deformation and can influence the surface integrity of machined components, which is of great interest to both academic communities and industries. This paper summarizes the state of the art in modeling approaches for the effect of the microstructures and its evolution during metal-cutting processes. The aim of this paper is to analyze the advantages and drawbacks of current methods to improve modeling work and direct future orientations. First, dominant numerical modeling approaches for metal-cutting processes are reviewed. The finite element method (FEM) and mesh-free methods widely applied in professional research are discussed. Following this, approaches to modeling the effect of microstructures and their evolution are reviewed for two major categories—homogeneous field distribution and heterogeneous characteristics. Both the advantages and disadvantages of these two categories are analyzed and discussed in detail. Experimental techniques based on advanced characterization approaches to the validation of pertinent models are also discussed. Finally, a brief summary is presented and an outlook for future work is delineated. [Display omitted] • Numerical modeling approaches with the consideration of microstructure features towards metal cutting are reviewed. • Modeling through treating microstructures as homogeneous characteristics and pertinent validation techniques are reviewed. • Modeling of heterogeneous microstructure evolution in metal-cutting and pertinent characterization techniques are reviewed. • Future orientations of modeling the effect of the microstructure and its evolution in metal-cutting are recommended. [ABSTRACT FROM AUTHOR]