Chip formation process in the deformation zone and contact condition at the chip-tool interface have been modeled through the direct observation of the orthogonal machining process using high speed photography.

The behavior of material undergoing extreme deformation has been modeled through the direct measurement of strain and temperature distributions in the deformation zone during machining.

The intrinsic size effect in machining has been modeled using the strain gradient plasticity theory. The strain gradient values directly measured using PIV during machining was employed for the simulation.