Unified cutting force model for turning, boring, drilling and milling operations

A unified cutting mechanics model is developed for the prediction of cutting forces in milling, boring, turning and drilling operations with inserted tools. The insert and its orientation on a reference tool body are mathematically modeled by following ISO tool definition standards. The material and cutting edge geometry-dependent friction and normal forces acting on the rake face are transformed into reference tool coordinates using a general transformation matrix. The forces are further transformed into turning, boring, drilling and milling coordinates by simply assigning operation specific parameters. The unified model is validated in cutting experiments.

► Unified mechanics of turning, drilling and boring are modeled.
► ISO standards are used in defining the tool parameters.
► The process forces are predicted using one set of expressions.