Abstract
Abstract In this paper, a model of three-dimensional cutting is developed for predicting three-dimensional tool forces and the chip flow angle. The approach consists of coupling an orthogonal finite element cutting model with an analytical model of three-dimensional cutting. The finite element model is based on an Eulerian approach, which gives excellent agreement with measured tool forces and chip geometries. The analytical model was developed by Usui, in which a minimum energy approach was used to determine the chip flow direction. The model developed by Usui required orthogonal cutting test data to determine the tool forces and chip flow angle. In this paper, the finite element model is used to supply the orthogonal cutting data for Usui’s model. With this approach, a predictive model of three-dimensional cutting can be developed that does not require measured data as input. Cutting experiments are described in which excellent agreement was found between measured and predicted tool forces and chip flow angles for machining of AISI 1020 steel.
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