Modeling of cutting force coefficients in cylindrical turning process based on power measurement

Abstract

The cutting force is an important physical quantity in metal cutting, and the cutting force coefficients are the basis for establishing the cutting force model. In this paper, the relation between the cutting power and the cutting force coefficients is established. A cutting power model was established with a linear relationship between the spindle power and material removal rate (MRR). The power-based model of the main cutting force coefficients is proposed by extracting the linear equation coefficients of the power-MRR function. The power-based model of feed force coefficients is established as a quadratic polynomial equation between the motor power of the feed axis and feed rate. And the cutting force coefficients and the edge force coefficients of feed force are expressed respectively by the two orders of coefficients of the equation. The thrust force coefficients are indirectly calculated from the relation between tangential cutting force and thrust force with friction angle of tool-chip. The power-based models were verified by a series of cutting tests regarding material properties, cutting parameters, and axial directions. The results show that the cutting force coefficients obtained by measuring the cutting power have good correspondence with that identified by dynamometer.