Prediction of turning performances using an equivalent oblique cutting model

Abstract

The main purpose of this paper is to predict the performances of the turning process using an equivalent oblique cutting model. Based on the real tool, an equivalent cut geometry is performed considering the effects of nose and edge radii. Edge direction and normal cutting angles, uncut chip thickness, and depth of cut were redefined by their equivalent values and then used as new inputs. Turning performances, such as cutting force components, cutting temperatures, and tribology parameters at the tool/chip interface, were predicted over a wide range of cutting conditions. The position of the maximum temperature at the tool/chip interface and its value are determined by solving the heat equation in the chip using the Finite Difference Method. Different assumptions were concluded, and the thermal problem is simply resolved using Laplace transform. It was determined that the maximum tool/chip interface temperature is situated far from the cutting edge about \(0.317{\mathrm{l}}_{\mathrm{c}}\). It was also found that the partition coefficient is strongly related to sliding speed and it decreases about 20% when chip velocity increases from 1 to 5 m/s. Acceptable agreement was concluded between experimental cutting force components and those predicted from the equivalent oblique cutting model. It can thus be concluded that the equivalent model of cut is highly recommended to predict turning performances.