The mystery of missing feed force - The effect of friction models, flank wear and ploughing on feed force in metal cutting simulations

Underestimated feed force is a known systematic error in cutting simulations. It is considered a consequence of inaccurate friction models, but there are indicators that friction is not the only reason for the error. In some cases, the value of Coulomb friction must be over 1.0 to compensate for the feed force and such values cause over-estimated chip thickness for example. In turning, the ploughing force of the tool is affected by the feed velocity, which changes with the work diameter when cutting speed is constant. In addition, the edge geometry of the tool affect the ploughing force. In this paper, friction, edge geometry and the plough force are investigated with experiments and simulations to identify their effect on feed force.