A Dual-Mechanism Approach to the Prediction of Machining Forces, Part 1: Model Development

Abstract

A cutting-process model addressing the chip removal and edge ploughing mechanisms separately yet simultaneously is presented. The model is developed such that it is readily applicable in an industrial setting, its coefficients have physical meaning, and it can be calibrated with a concise quantity of orthogonal cutting data. The total cutting and thrust forces are each the summation of its individual components acting on the rake face and clearance face. These components are calculated using the rake and effective clearance angles from the normal and friction forces acting on each of these tool surfaces. These normal and friction forces are calculated by the chip removal and edge ploughing portions of the model, respectively, using four empirical coefficients. To calculate the clearance face forces, the interference volume is required, the calculation of which is based on a geometrical representation of the clearance face interference region. This representation is characterized in part by the depth of tool penetration, which is influenced by thermal energy generation and is therefore determined using a fifth empirical model.

Effect of finite edge radius on ductile fracture ahead of the cutting tool edge in micro-cutting of Al2024-T3

“…Based on this understanding of ploughing and the stagnation point concept, several researchers have come up with analytical models for machining [15][16][17]. Slip line field models incorporating the ploughing-type of metal flow have also been reported [18,19].…”

A Method to Determine Cutting Force Coefficients in Turning Using Mechanistic Approach

“…A direct calibration method is used to determine the same. A series of machining tests are conducted to establish the cutting force coefficients over a range of cutting conditions [14]. The cutting constant is directly related to the mechanics of metal cutting and tool-workpiece interaction which is shown in the Fig.…”

The Evaluation of Analytical Models for Orthogonal Cutting Process

“…The actual function is then determined by fitting experimental data in a process called calibration. Calibration can be based on simple orthogonal or oblique machining set-ups; geometric transformations can then be applied to predict cutting forces for a complex, three-dimensional machining process [29].…”

“…Mechanistic modeling is an analytical approach based on a semi-empirical method capable of accurate prediction of cutting forces in a wide range of complex machining operations [28][29], [5]. This approach is based on the assumption that cutting forces are proportional to the uncut chip area.…”