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Abstract. To design a cutting tool and thus to assign its proper geometry, select the proper tool material and machining regime, one needs to know the physical essence of a metal cutting process starting with its definition and finishing with the easiest way to accomplish the objective of this process. This chapter provides guidelines to distinguish the metal cutting process commonly referred to as metal cutting among other closely related manufacturing processes and operations. It presents the known results and compares them with those used in other forming processes/operations. It argues that, if the usual notions are used, the metal cutting process does not have any distinguishing features. Analyzing what went wrong with the existing notions in metal cutting, this chapter provides a physicallybased definition of the metal cutting process. Using the introduced definition, this chapter for the first time describes explicitly the role of cutting tool geometry in the metal cutting process that sets the stage for better understanding of other chapters in this book. Because in the development and implementation of any cutting tool experiment remains essential, the complete hierarchical system of tool testing is also discussed and the most useful similarity numbers used in testing are introduced and explained.

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