Computer-Aided Predictive Models for Fundamental Rotary Tool Cutting Processes

Abstract

Mechanics of cutting analyses for fundamental ‘self-propelled’ and driven rotary tool cutting processes aimed at gaining an understanding of the practical rotary tool turning and face milling operations are presented. It is shown that these fundamental rotary tool processes can be directly related to the ‘classical’ orthogonal and oblique cutting processes used to study the fundamentals of conventional machining and develop predictive models for the more complex practical turning, drilling and milling operations. Based on the unified mechanics of cutting approach, computer-aided cutting models for predicting the force components, power and chip flow angle in the fundamental rotary tool processes are discussed, experimentally verified and numerically studied. The difficulties of extending these models to the practical rotary tool operations are briefly discussed.