Mechanistic force modeling of single point cutting tool in terms of grinding angles

The cutting tool angles have conventionally been presented using projective geometry in terms of the projections of cutting edges on respective planes, which makes the visualization of geometry difficult, particularly for complex tools. Modeling a cutting tool using the actual grinding angles can simplify the geometric definition of the tools and provide a comprehensive and simple definition of tools for downstream applications. The paper presents the 3D definition of the faces of a single point cutting tool (SPCT) in terms of 3D rotational grinding angles and maps the new tool nomenclature with the ASA, ORS and NRS nomenclatures. A mechanistic model is subsequently proposed to predict the forces in terms of the grinding angles, chip thickness and velocity using second degree polynomial function, unlike the conventionally used logarithmic ones. The model has been calibrated for HSS tool and Mild Steel workpiece combination for end turning of a tubular workpiece based on the regression analysis of a central composite design of the experiments. The results have been discussed and the model has been validated for a new set of experimental data. The model shows a good correlation to the observed results.

► Employs an advanced 3D nomenclature to model the geometry of single point cutting tools.
► The new tool signature is mapped onto the prevalent ASA, ORS and NRS systems.
► A mechanistic model is proposed for cutting forces in terms of grinding angles, feed and velocity.
► The model is calibrated for a specific tool-workpiece material combination and results discussed.
► Model has been validated for a random selection of 3D grinding angles, feeds and speeds.