Predictive modeling and optimization of turning operations with complex grooved cutting tools for curled chip formation and chip breaking

This paper presents a summary of the most recent developments in predictive modeling and optimization of turning operations. While almost all previous models for turning operations deal only with flat-faced tools, the present work presents the more practical turning operations involving the use of c omplex grooved tools for producing 3D chip flow, curl and breaking. The pap er provides details of the analytical modeling efforts including the develo pment and validation of the universal slip-line model for 2D curled chip fo rmation. Side-curl and up-curl dominated 3D chip formation process is then discussed with case studies for predicting 3D chip curl using a newly devel oped Equivalent Toolface (ET) model followed by a description of analytical models and experimental work on 2D and 3D cyclic chip formation and chip b reaking involving variable tool-chip contact. At the end, new tools and tec hniques used in the machining process optimization for optimum machining pe rformance including cutting tool selection are presented in the paper. This covers nonlinear programming methods, genetic algorithms and the use of tr aditional and hybrid models for single-pass and multi-pass turning operatio ns performed using complex grooved tools. The major machining performance m easures considered in the optimization process include cutting forces, tool -wear/tool-life, surface roughness, chip-form/chip breakability and materia l removal rate. The paper places an emphasis for a machining systems approa ch to include the integrated effects of workpiece, cutting tool and machine tool.