Cutting force prediction based on a curved uncut chip thickness model

TL;DR

This paper introduces a curved uncut chip thickness model to predict cutting forces in machining, accounting for complex geometries and providing a computationally efficient solution validated by real cutting tests.

Contribution

The paper presents a novel curved path model for uncut chip thickness that improves cutting force prediction for complex tool geometries without extensive simulations.

Findings

Model accurately predicts cutting forces for complex geometries

Cutting force components are sensitive to modeling assumptions under extreme parameters

The approach is computationally efficient and consistent with classical observations

Abstract

The curved uncut chip thickness model is presented to predict the cutting forces for general uncut chip geometries. The cutting force is assumed to be distributed along a curved path on the rake face of the cutting tool, which makes the solution computable for inserts with nose radius and more complex cutting edge geometries. The curved paths originate from a basic mechanical model (a compressed plate model), which is used to mimic the motion of the chip on the rake face of the tool without performing real cutting simulations. Consequently, actual cutting forces are predicted using orthogonal cutting data and the orthogonal-to-oblique transformations. The solution satisfies the classical observations and assumptions made on the chip formation process, it is mathematically unique, free of inconsistency and computationally effective. Case studies are presented on real cutting tests. The results highlight that cutting force components can be sensitive to modeling assumptions in case of extreme machining parameters.