Metals (Jan 2022)
Comprehensive Investigations of Cutting with Round Insert: Introduction of a Predictive Force Model with Verification
Abstract
The observation and prediction of cutting forces are key questions when planning manufacturing technologies. In this paper, all three force components are investigated in the case of turning with round insert. The specific cutting forces were used and adapted for the round insert. Two easily calculable parameters of the undeformed chip cross-section were introduced (heq—equivalent chip thickness and leff—total length of the engaged cutting edge). The dependency of the specific force components was examined with regards to heq and leff. The main goal was to generate new empirical force models for each component, which helps to estimate their values in a wide range of technological parameters from fine to rough machining. The application of the models was confirmed by a case study where 11SMn30 + C (1.0715) was investigated. The examined interval of cutting parameters was: for feed, f = 0.12… 0.6 mm, and for depth of cut, ap = 1.2… 4.8 mm. The novelty of the article is that the introduced new force models based on the geometric parameters characterizing the undeformed chip cross-section of round insert are proper for predicting the cutting force components in the technological process planning with an accuracy high enough—for main cutting force (Fc) −3.79%… +4.43%, for feed force component (Ff) −5.4%… +5.99%, and for radial force component (Fr) −4.49%… +4.77%.
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