Predictive Force Models for Orthogonal Cutting Incorporating Tool Flank Wear

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Author(s) Tertsegha Daniel Ipilakyaa | Livinus Tyovenda Tuleun | David Terfa Gundu
Pages 435-443
Volume 4
Issue 7
Date July, 2014
Keywords Orthogonal Cutting; Tool Flank Wear; Machining; Cutting Force; Models

Abstract

In this paper, predictive force models for orthogonal metal cutting incorporating tool flank wear were developed on the basis of experimental investigations. CNC lathe machine (T6-series) was used to cut mild carbon steel CS1030. Cylindrical workpieces were prepared with wall thickness of 3mm and diameter of 100mm. Four levels of cut thickness (0.1, 0.17, 0.24 and 0.31mm) were tested at three levels of cutting speed (100, 150 and 200m/min) and three levels of tool rake angles (-5,0 and 5^0). Four levels of tool wearland sizes (0, 0.2, 0.4, 0.6mm) were selected where wearland size “0mm” represents sharp tool. The results show that wear of tool flank caused an increase in the rubbing or ploughing force on the wear land (between 802.9-2333.2N for power force and 610.9-1455.5N for thrust force). Orthogonal cutting force models are proposed which makes full use of the classical thin shear zone analysis for "sharp" tools, and may form the basis for developing the predictive force models in practical machining operations. The results also show an increase in the force components as a result of tool flank wear with indication of the thrust force exhibiting more sensitivity to cutting tool flank wear. The results may also be used for developing tool condition monitoring strategies.

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