An Analytical Modeling Of The Metal Cutting Process

As well-known as the cutting temperature and its distribution in thecutting zone are a critical factor that significantly affects tool life and degrades partaccuracy during varying cutting processes. From the standpoint of the common issues withthe limitations that existed in the cutting temperature models and experimentalmeasurements. In this paper, a model under different cooling conditions withthermo-mechanical coupling effects is proposed to predict cutting temperature distributionas well as the relevance parameters in the cutting zone. The understanding of temperaturedistribution along the tool-chip interface is important for machining process planning andtool design. Among many temperature modeling studies, cutting temperature modelingunder different cooling conditions are rarely considered. Based on the oblique moving bandheat source of Jaeger and Komanduri and Hou’s approach, this paper presents an analyticalcutting temperature modeling approach that considers the combined effect of the primaryand the secondary heat sources and solves the temperature rise along the tool-chip interfacebased on the non-uniform heat partition ratio and non-uniform heat intensity along theinterface under different cooling conditions. Force modeling in metal cutting is importantfor a multitude of purposes, including thermal analysis, tool life estimation, chatterprediction, and tool condition monitoring. In this model, the effect of tool rake angle oncutting forces has been addressed systemically and analytically. Furthermore, to generalizethe modeling approach, different formulations of chip velocity is applied in the modifiedOxley’s approach. The proposed model is verified based on the published experimental dataof the conventional turning process and data of finite element method, it shows satisfactoryaccuracy. The research achievements can be used to cutting parameters optimization andmachining process monitoring as well as improving tool life.