The ploughing forces (PFs) are one of the important parameters for calculating the tool life. They directly affect the stress on the tool flank face and are responsible for wear and tear conditions of the cutting tool as well. In this study we attempted to find the impact of cutting speed on PFs, that is, the relation between cutting speed and PFs. In this paper, the ploughing forces were estimated by a new comparison method in which forces at different point of contact areas are added (sum of forces) to get the PFs accurately. The accuracy of PFs estimated with this method will be better than previously used methods. This paper presents the measurement results of the PFs when turning stainless steel, structural steel and aluminum alloy materials. The results of experimental studies showed that an increase in cutting speed ranging from 50 to 200 m/min resulted in increase in PFs by 1.4–3.2 times when turning with different flank wears.
Currently, two methods are most often used to determine the ploughing forces: the extrapolation on zero uncut chip thickness and the comparison of total forces at different flank wears. These methods assume that the processes occurring on the front surface of the tool cause no effect on the processes transpiring on the rear surface. This study attempted to prove the connection between these processes, and both methods cannot be used to find the ploughing forces. The results showed that the increase in the uncut chip thickness causes the increase in the ploughing forces. This finding proves the connection between the processes occurring on the front and rear surfaces. To reveal the ploughing forces, we suggest using the third method, the comparison method of the total forces for different contact areas, which is based on the dependence of the processes on the rear surface on the processes on the front surface.
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