A Simplified Model for Ploughing Forces in Turning

Abstract

This paper aims to provide experimental data in support of a modified theoretical model for quantifying the effect of cutting tool edge geometry on machining forces. A previously published slip-line model is simplified and extended to the case of turning. Several sets of machining experiments were run with customfabricated cutting inserts of varying edge hone radius and chamfer geometry. Cutting forces were measured using a dynamometer during cutting.Results show that varying edge geometry can have a major effect on cutting forces.The developed model effectively captures the edge phenomenon and its effect on cutting forces and also offers a glimpse of how the edge geometry can affect dynamic process damping.

A Study on Cutting Force of Machining In Situ TiB2 Particle-Reinforced 7050Al Alloy Matrix Composites

“…Based on the slip line field method, the ploughing forces, such as F cp in the cutting direction and F tp along the feed direction, could be determined by considering the edge radius r n [31]:…”

Analytical modeling of chip geometry and cutting forces in helical ball end milling of superalloy Inconel 718

“…(3)], undeformed chip width [Eqs. (13) and (14) )]. Therefore, the deformed chip thickness is given by,…”

“…Besides, it is also understood from the literature that chip formation in high speed machining of Inconel 718 involves formation of adiabatic shear bands [11] in chips, which consume majority of the energy required for the material deformation in machining. Further, the machining process involves ploughing forces too that consume a good portion of energy, which does not contribute to the cutting operation [13]. Therefore, this model involves consideration to the shear band spacing and ploughing forces that occur during machining of superalloys while evaluating instantaneous cutting forces analytically (see approach of model in Fig.…”

“…The mean tool temperature in machining evaluated using Kronenberg's analysis [12] is considered as primary shear zone temperature for this analysis. Consideration of ploughing force coefficients [13]. Cutting force evaluation with respect to the instantaneous tool rotation angle.…”

“…In order to determine the force components due to ploughing, the equations in Ref. [13], which are based on a slip-line field model for a rigid wedge sliding on a halfspace and for orthogonal cutting have been appropriately modified to suit the proposed model. The ploughing force components acting in the direction of cutting, F cp , and thrust, F tp , directions are given by [13],…”