Experimental and Analytical Investigation into Cutting Forces during Turning of EN-31 Steel in Different Machining Conditions

Abstract

Metal cutting is the way of processing the workpiece with tool having sharp cutting edges of different materials generating chips of different shapes and sizes. In present era of industry 4.0, metal machining should not be unrated during processing of hard grades metals and superalloys where large amount of cutting forces are generated. Also, the measurement of cutting forces provides the basic of economical machining and hence accurate evaluation in experimental and analytical manner has great importance. The traditional models of metal cutting have disagreement with experimental results due to missing of important mechanics terms. With the development of digital technology, the errors in calculation of cutting force have also been shortened due to consideration of terms absent in conventional models. In present investigation, the cutting forces have been evaluated experimentally using dynamometer and analytically with Astakhov’s methodology during turning of EN-31 steel. The results revealed that 12.9% observations have deviation more than 20%, whereas 16.67 % has zero deviation. Further, the feed rate has more influence on cutting forces as compared to speed and nose radius. In addition, the minimum quantity lubrication (MQL) of vegetable oil has lowered the cutting forces appreciably compared to dry machining.