Abstract
Prediction of cutting forces in finishing conditions is becoming essential for the automotive industry, in order to achieve the desired surface integrity and keep controlled phenomena as chatter, especially in workpieces with small thickness walls manufactured by die casting. For predictions, orthogonal to oblique models are widely used, which require a material database as input data. Databases found in the literature have been proven to predict forces accurately in roughing conditions. However, several geometric parameters of the inserts are not taken into account, which could lead to inaccurate predictions in finishing conditions. In this paper, the effects of the cutting edge radius and clearance angle are analysed over the cutting and feed forces during orthogonal turning. A material database for A-356 aluminium alloy is developed following a methodology in accordance with previous research. Finishing face milling tests are carried out for validation, obtaining good agreement with modelled forces.
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