Analytical modeling of metal cutting process with self-propelled rotary tools

Abstract

The usage of rotary cutting tools is an effective technique to machine difficult to cut materials, even in a dry environment. In this technique, the tool is rotating around its axis, which offers a heating-cooling cycle for each portion of the cutting edge. Besides, the tool wear is dramatically decreased and distributed over the whole circumference of the round insert due to the tool motion. In this paper, an analytical-based model is developed to predict the cutting forces and tool rotational speed, which is a significant design aspect when machining with self-propelled rotary tools (SPRT). To minimize the used assumptions and maintain high results accuracy, the bearing friction of the cutting insert is considered. Accordingly, the tool's rotational speed is reduced compared to the assumption of bearing frictionless. Equivalent oblique cutting approach is applied, and Oxley's theory is extended to predict the cutting forces for the SPRT. The model has been validated with previously published experimental results.