Edge forces in metal cutting : fundamental analysis and experimental verification

Abstract

In metal cutting, some of the generated forces do not contribute to chip formation and where chip is not developed per the classical cutting mechanics. Such forces are referred to as parasitic or plowing forces and are induced mainly as a result of the finite sharpness of the tool (cutting edge radius) and the tool's land (flank). Determining the magnitude of parasitic forces is essential to developing a better understanding of the mechanics and the physics in such applications that involve cutting at very small feed values (e.g., micro-machining and vibration-assisted- micro-machining. It is well recognized that plowing forces increase with tool wear. This research estimates these forces while employing analytical and numerical simulations. Extensive experimental is utilized to verify the simulated values of these parasitic forces where an experiment is designed to measure these forces as function of several cutting parameters. The developed analytical model relates the parasitic forces to geometric and process parameters such as cutting-edge radius, feed, and speed.