A DUAL-MECHANISM APPROACH TO THE PREDICTION OF MACHINING FORCES .1. MODEL DEVELOPMENT

A cutting-process model addressing the chip removal and edge ploughing mechanisms separately yet simultaneously is presented. The model is d eveloped such that it is readily applicable in an industrial setting, its coefficients have physical meaning, and it can be calibrated with a concise quantity of orthogonal cutting data. The total cutting and t hrust forces are each the summation of its individual components actin g on the rake face and clearance face. These components are calculated using the rake and effective clearance angles from the normal and fri ction forces acting on each of these tool surfaces. These normal and f riction forces are calculated by the chip removal and edge ploughing p ortions of the model, respectively using four empirical coefficients. To calculate the clearance face forces, the interference volume is req uired, the calculation of which is based on a geometrical representati on of the clearance face interference region. This representation is c haracterized in part by the depth of tool penetration, which is influe nced by thermal energy generation and is therefore determined using a fifth empirical model.