Prediction of surface integrity using Flamant-Boussinesq analytical model

Surface integrity prediction of hard machining using PCBN cutting tools remains a major topic for many high value added applications. A Flamant-Boussinesq (FB) analytical model has initially been applied for surface integrity prediction in orthogonal cutting. In order to extend this model to the general case of 3D cutting process, a cutting force model was developed and incorporated into the FB model. This one was then used to evaluate the plastically deformed layer thickness induced by 3D round cutting tools. It was validated by comparing the predicted plastic strains with the micro hardness distribution induced by 3D cutting tests.