Abstract
Machining process models can be used to predict cutting force/power and further optimize the process parameters. In this work, a mechanistic cutting force model for turning processes is developed. In order to accurately predict cutting forces, the cutting tool edge is discretized and an approach for calculating the chip load corresponding to each discretized edge segment is developed. Approach for calculating effective tool angles is also developed considering effects of the tool corner radius and the change of feed direction. By using the yield shear stress of the work material, the friction angle between work and tool material, the chip load and the effective tool angles for each tool edge segment, the distributions of the turning forces and force intensity along the tool edge can be predicted. Turning cases of straight turning, contour turning, taper turning and facing are tested and the model outputs include the distributions of the instantaneous effective tool angles, chip load, cutting force coefficients and force intensity. Test results for straight turning and contour turning operations are analyzed to demonstrate the model capability. The distributions of force and force intensity on tool edge provide useful information for prediction of turning forces/power and potential further prediction of tool wear/life.
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