Quantitative understanding and prediction of cutting forces using worn tools is important to cutting process thermal modeling, tool life estimation, chatter prediction, and tool condition monitoring purposes. In this paper, a modeling approach in 3D oblique cutting is presented. The cutting configuration is featured with worn chamfered tools with a rounded tool nose under hard turning conditions, which are characterized by small feed rate and small depth of cut using a chamfered nose radius tool. The whole cutting edge is discretized into a number of elements, which follow the same chip flow angle. The force information is modeling by collectively considering the forces on each discretized elementary cutting edge based on a worn tool force model. The proposed model is further validated with the experimental hard turning studies. It is found that the chip flow angel does not change noticeably with tool wear. The predicted cutting and feed forces are relatively accurate compared with the predictions of the thrust forces. The force modeling accuracy is expected to be further improved by accurate consideration of the flank and crater wear geometry and generalization of the interaction forces between the discretized chip elements along the tool nose of the chamfer zone in the future studies.

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