Orthogonal cutting is probably the most studied machining operation for metals. Its simulation with the Finite Element Analysis (FEA) method is of paramount academic interest. 2D models, and to a lesser extent 3D models, have been developed to predict cutting forces, chip formation, heat generation and temperature fields, residual stress distribution and tool wear. This paper first presents a brief review of scientific literature with focus on FEA modelling of the orthogonal cutting process for steels. Following, emphasis is put on the building blocks of the simulation model, such as the formulation of the mechanical problem, the material constitutive model, the friction models and damage laws
