Mechanistic Force Models for Chip Control Tools

Abstract

A mechanistic modeling approach to predicting machining forces for grooved tools is developed. The models are based solely on the grooved tool geometry and the specific normal cutting energy and friction energy for flat tools. Special grooved tools (M2 grade HSS) were designed and fabricated and orthogonal cutting tests were performed to validate the model. The workpiece material used was Al 6061-T6. The force predictions from the model are found in good agreement with the measured forces. The effects of groove design parameters on the cutting forces are also determined.

Fem Investigation for Orthogonal Cutting Process With Grooved Tools–technical Communication

“…In present work, the land length has not been considered as a variable rather than uncut chip thickness, thus, the ratio of uncut chip thickness to land length is still a variable. These simulation and experimental results of Parakkal et al (2002) and Zhu et al (1999) also show that the more the contact area between chip and tool is, the less the chip backflow angle is.…”

“…The relation between chip back-flow angles in above simulation and tool land lengths agrees with results of Parakkal et al (2002); and Zhu et al (1999), where the ratio of uncut chip thickness (t) to land length (h) was used to integrate cutting process and tool parameters. In present work, the land length has not been considered as a variable rather than uncut chip thickness, thus, the ratio of uncut chip thickness to land length is still a variable.…”

“…Strenkowski and Athavale (1997) simulated a partially constrained Eulerian orthogonal cutting by finite element method. Parakkal (2002) and Zhu (1999) calculated orthogonal and oblique turning process and cutting force for grooved tools by defining a set of equivalent groove parameters. Jawahir (2000) investigated the grooved tool failure using the equivalent tool face (ET) model.…”

Analysis of an equivalent tool face for the cutting speed range prediction of complex grooved tools

“…Nevertheless, a unique validated model considering both friction conditions has not been proposed. Others methodologies described by Bailey [23] and Zhu et al [11] are based on shear angle and stress parameters. However, these parameters are often difficult to determine in industrial environments.…”

“…A number of cutting forces models were developed beginning by Merchant [6], Martellotti [7,8], and Sabberwal [9]. Mechanistics models became popular in the last 20 years and include models for different process geometries [8,9], cutting conditions [10], chip control [11,12], surface locating errors [13], cutter deflection [14], and cutting force prediction [15]. In all cases it is recognized that these models need to be carefully calibrated using costly experiments for each tool-work-material combination.…”