Analytical prediction of cutting forces in cylindrical turning of 304 stainless steel using unequal division shear zone theory

Abstract

In order to establish a more accurate prediction model of turning forces, this paper proposed an analytical model for cylindrical turning with the consideration of the effect of the main cutting edge angle and the nose radius. Meanwhile, the unequal division shear zone theory in orthogonal free cutting is extended and applied to the oblique non-free cutting in the interaction between the chip units. To take into account the real tool nose geometry, the engaged part in the rounded nose is discretized into a set of cutting edge units. The geometrical parameters associated with the cutting edge units are analysed by using the coordinate transformation approach. Then, the improved oblique cutting model is developed for each cutting edge unit to acquire the component forces along the tool rake face. Finally, the resultant cutting forces in the turning process are calculated by the numerical integration method. To verify the effectiveness of the proposed model, the turning force experiment of 304 stainless steel was carried out by changing the cutting conditions, the main edge cutting angle and the nose radius. Through the comparative analysis between the measured results and the calculation values of the proposed model, it was found that the analytical prediction of cutting force is in good agreement with the experiment.

Different Aspects of Machinability in Turning of AISI 304 Stainless Steel: A Sustainable Approach with MQL Technology

“…The prediction model of the temperature field at the tool-chip interface can support better cutting processes, especially surface integrity, and transition life, and improve machining properties by preventing thermal distortions on the workpiece [41,42]. An analytical prediction model of turning forces on turning AISI 304 was proposed by Li and Zhang [43]. The results of the prediction model of the temperature field and the cutting force in machining are in good agreement with the experiments.…”

Performance analysis of twin-layer AlTiN and TiCN coated inserts during high speed turning of SS304 with synthetic coolant at 0°C

“…The smooth flow of chips over the face results in less entanglement of the tool with chips, which protects the tool edge from getting distorted. 28…”