How to reduce cutting force of tool

[Vxxxxx]

I am performing 2D othorgonal cutting simulation of a certain material and I realised that the cutting force in the x-direction(reaction force on the tool) is two times larger than the results obtained from the experiment.

I tried reducing the friction coefficient but the cutting force reduced only by abit (5%). Right now, I am trying to reduce the value of damage evolution (shear damage) to see if it makes a bigger difference.

Is there any other effective ways to reduce the reaction force (RF1) of the tool in the simulation in order to get closer to experiment values? Thank you.

 

[FEA way]

Can you attach pictures with contour plots of this reaction force (RF1) and stresses (on the deformed shape) ? How and where is the force measured in the experiment ?

 

[FEA way]

At which point of the model have you measured this reaction force ? Can you show it in the picture ? And what is the title of this article ? I would take a look at it.

 

[Vxxxxx]

This reaction force is measured at the tip of my tool, and my tool is set as rigid body, so it doesnt matter where I set it. As for the article, I am sorry but this is a master thesis written in Chinese. The author actually did the same simulation and got a closer results than mine. (within 20% difference)