3D Cutting Model

We have been developing 3-D cutting models that can be used to predict the 3-D tool forces and the chip flow angle in turning. These models are based on the finite element technique, which allows us to predict the tool forces, the chip shape and flow angle, the cutting pressure on the tool edge, and the temperatures in the workpiece, chip, and tool. As an example, a turning operation was analyzed for a tool with two cutting edges and an included nose radius. The figure shows a comparison between the predicted and measured tool forces for a commercial insert (TPG-3) for a feed of 0.165 mm/rev, a speed of 1.6 mm/sec, and a depth of cut of 0.76 mm. The figure shows that excellent agreement can be achieved with these models for a range of tool nose radii. Note that the out-of-plane or transverse tool force increases with the nose radius. This is expected because a larger radius tool will engage a greater portion of the workpiece, thus increasing both the chip flow angle and the transverse force. Similar agreement was found for other cutting conditions including slower cutting speeds and larger depths of cut.

3D Chipflow:

Forces vs. Tool Nose Radius Plot:
 

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