In this paper a mechanistic model for contour turning is presented. A chip load model is developed for general contour turning process. Analytical expressions are derived for chip thickness and chip load in a simple case of contour turning. A generalized numerical procedure is also developed for evaluation of various cutting parameters like cutting velocity, effective lead angle, chip thickness, chip load, normal rake angle, and chip flow angle. The effects of these parameter variations on the cutting forces are analyzed. As a special case hemispherical turning is considered for model validation. Simple straight turning tests are employed for model calibration. The interference between tool and workpiece and ploughing are identified as possible causes for an abrupt increase observed in the cutting forces. Use of circular inserts with large nose radius eliminates this problem. Experimental validation is done with circular inserts.

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