| Article ID | Journal | Published Year | Pages | File Type |
|---|---|---|---|---|
| 780507 | International Journal of Machine Tools and Manufacture | 2012 | 9 Pages |
The development of force models is important in understanding the effects of tool edge geometry where the tool edge radius is of similar value to the depth of cut. In this paper it is demonstrated that both the rounding of the tool edge and the rounding of the tool nose affect the chip formation process and the quality of the machined surface.The distribution of unit forces on the nose of a tool is presented in detail. The main assumption in all the considerations was constant temperature conditions in the cutting zone, maintaining the thermo-mechanical properties of the work material at a constant level. The experiment was conducted for free and non-free turning, and in both cases the temperatures and forces were measured.For free cutting the distribution of unit forces on the tool edge rounding was investigated—the minimal thickness of cut and characteristic equations for forces Fc and Ff were determined. Then the unit forces distribution was recalculated for the case of non-free turning with rounded tool nose. The summed forces for non-free turning were compared with measured values, for verification of the cutting force model.The distribution of unit forces along the tool nose revealed nonlinearities influencing tool and machined surface integrities. The unit forces acting on the rake face were established to determine the length of the active part of the tool where the conditions for chip formation were favorable. Distribution of unit forces acting on the rake face in the reverse direction indicated the conditions in which a chip was pushed away from the transient surface.The distribution of unit forces acting on the flank face in the feed direction was found to determine the machined surface quality. The range of negative values of unit forces defined the conditions for moving away of the non-machined material (under the condition hj ► Data for modeling non-free cutting are suitably selected from studies of free cutting. ► Modeling the distribution of unit forces is taking account of constant temperature conditions. ► Obtained image of the distribution of unit cutting forces is universal in nature. ► Distribution of unit forces depends on the tool geometry.
