Assessment of the Adequacy of the Definition of Cutting Forces for the Purpose of Minimizing Energy Consumption in Machining Processes

Abstract

Minimizing energy consumption in the processing of parts on metal-cutting equipment is most effective at the stage of designing the content of operations. Important in this process is the precise determination of the initial parameters - cutting forces. This parameter allows you to plan both energy consumption and perform additional calculations for the deformation of the tooling and workpiece in order to predict the geometric accuracy of the machined part. The article presents the results of experiments on measuring the circumferential cutting force during milling operations of an aluminum alloy workpiece with an end mill. The measurements were carried out by an indirect method - by recording the electrical power on the spindle and then calculating the circumferential cutting force. Theoretical analysis of the methods of calculation of cutting forces showed significant differences between the results obtained by domestic methods and recommendations of world manufacturers of cutting tools. Statistical analysis of the results of calculations based on reference data and measurements made it possible to assess the adequacy of the known methods for calculating cutting forces in order to minimize energy consumption in operations of processing parts on metal-cutting equipment