Title: A methodology to estimate the forces on the tool insert in finish hard turning

Authors: Gaurav Bartarya; S.K. Choudhury

Addresses: Mechanical Engineering Department, Harcourt Butler Technological Institute, Kanpur, U.P. 208002, India. ' Mechanical Engineering Department, Indian Institute of Technology, Kanpur, U.P. 208016, India

Abstract: The work presents a methodology to predict the forces on a worn cutting tool insert in finish hard turning when cutting action is limited to the round nose of the insert. The forces acting on the sharp tool, due to material shear at the cutting edge, were estimated using minimum energy criterion. The induced forces due to chip tool rubbing were estimated using the rake face normal and shear stresses. Instantaneous flank wear was used to estimate the increase in tool forces due to rubbing at the flank-work interface. The flank wear is assumed to be homogeneous all over the tool nose involved in cutting. Machining parameters and the data related to the tool and workpiece material used in the model were taken from a previous work that used an equivalent side cutting edge angle to model the worn tool forces. Force estimation from the proposed model was found to be in coherence with the predictions and measured forces from the referred work.

Keywords: wear force models; finish hard turning; minimum energy criterion; machining; tool inserts; tool wear; force estimation; modelling; flank wear.

DOI: 10.1504/IJMMM.2012.046887

International Journal of Machining and Machinability of Materials, 2012 Vol.11 No.3, pp.280 - 296

Received: 07 Jul 2010
Accepted: 17 Feb 2011

Published online: 23 Aug 2014 *

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