Orthogonal cutting is probably the most studied machining operation for metals. Its simulation with theFinite Element Analysis (FEA) method is of paramount academic interest. 2D models, and to a lesserextent 3D models, have been developed to predict cutting forces, chip formation, heat generation andtemperature fields, residual stress distribution and tool wear. This paper first presents a brief review ofscientific literature with focus on FEA modelling of the orthogonal cutting process for

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... ls. Following,emphasis is put on the building blocks of the simulation model, such as the formulation of the mechanicalproblem, the material constitutive model, the friction models and damage laws