A cutting-process model addressing the chip removal and edge ploughing mechanisms separately yet simultaneously is presented. The model is developed such that it is readily applicable in an industrial setting, its coefficients have physical meaning, and it can be calibrated with a concise quantity of orthogonal cutting data. The total cutting and thrust forces are each the summation of its individual components acting on the rake face and clearance face. These components are calculated using the rake and effective clearance angles from the normal and friction forces acting on each of these tool surfaces. These normal and friction forces are calculated by the chip removal and edge ploughing portions of the model, respectively, using four empirical coefficients. To calculate the clearance face forces, the interference volume is required, the calculation of which is based on a geometrical representation of the clearance face interference region. This representation is characterized in part by the depth of tool penetration, which is influenced by thermal energy generation and is therefore determined using a fifth empirical model.

1.
Albrecht
P.
,
1960
, “
New Developments in the Theory of the Metal-Cutting Process—Part I. The Ploughing Process in Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
82
, pp.
348
358
.
2.
Albrecht
P.
,
1961
, “
New Developments in the Theory of the Metal-Cutting Process—Part II. The Theory of Chip Formation
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
83
, pp.
557
571
.
3.
Cook
N. H.
,
1959
, “
Self-Excited Vibrations in Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
81
, pp.
183
186
.
4.
Delio, T., Tlusty, J., Smith, S., and Zamudio, C., 1990, “Stiffness, Stability, and Loss of Process Damping in High-Speed Machining,” Proc., ASME Symposium on Fundamental Issues in Machining in Honor of B. F. von Turkovich, PED-Vol. 43, pp. 171–191.
5.
Endres, W. J., 1992, “A Dual Mechanism Approach to the Prediction of Machining Forces in Metal-Cutting Processes,” Ph.D. Thesis, University of Illinois at Urbana-Champaign.
6.
Endres, W. J., Sutherland, J. W., DeVor, R. E., and Kapoor, S. G., 1990, “A Dynamic Model of the Cutting Force System in the Turning Process,” Proc., ASME Symposium on Monitoring and Control for Manufacturing Processes, PED-Vol. 44, pp. 193–212.
7.
Ernst
H.
, and
Merchant
M. E.
,
1941
, “
Chip Formation, Friction, and High Quality Machined Surfaces
,”
Trans. ASM
, Vol.
29
, pp.
299
328
.
8.
Kececioglu
D.
,
1958
a, “
Shear-Strain Rate in Metal Cutting and its Effects on Shear-Flow Stress
,”
Transactions of the ASME
, Vol.
80
, pp.
158
168
.
9.
Kececioglu
D.
,
1958
b, “
Shear-Zone Temperature in Metal Cutting and its Effects on Shear-Flow Stress
,”
Transactions of the ASME
, Vol.
80
, pp.
541
546
.
10.
Kececioglu
D.
,
1960
, “
Shear-Zone Size, Compressive Stress, and Shear Strain in Metal-Cutting and Their Effects on Mean Shear-Flow Stress
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
82
, pp.
79
86
.
11.
Kobayashi
S.
, and
Thomsen
E. G.
,
1959
, “
Some Observations on the Shearing Process in Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
81
, pp.
251
261
.
12.
Kobayashi
S.
,
Herzog
R. P.
,
Eggleston
D. M.
, and
Thomsen
E. G.
,
1960
, “
A Critical Comparison of Metal-Cutting Theories With New Experimental Data
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
82
, pp.
333
347
.
13.
Lesieutre, B. C., 1992, “Network and Load Modeling for Power System Dynamic Analysis,” Ph.D. Thesis, University of Illinois at Urbana-Champaign.
14.
Masuko
M.
,
1953
, “
Fundamental Researches on the Metal Cutting (1st Report)—A New Analysis of Cutting Force
,”
Trans. Japanese Society of Mechanical Engineers
, Vol.
19
, pp.
32
39
.
15.
Masuko
M.
,
1956
, “
Fundamental Researches on the Metal Cutting (2nd Report)—The Theoretical Equation of the Indentation-Force Acting on a Cutting Edge and its Experimental Discussion
,”
Trans. Japanese Society of Mechanical Engineers
, Vol.
22
, pp.
371
377
.
16.
Merchant
M. E.
,
1944
, “
Basic Mechanics of the Metal-Cutting Process
,”
ASME Journal of Applied Mechanics
, Vol.
66
, pp.
A-168 to A-175
A-168 to A-175
.
17.
Nigm
M. M.
,
1981
, “
A Method for the Analysis of Machine Tool Chatter
,”
Int. Journal Machine Tool Design Research
, Vol.
21
, pp.
251
261
.
18.
Nigm
M. M.
, and
Sadek
M. M.
,
1977
, “
Experimental Investigation of the Characteristics of Dynamic Cutting Processes
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
99
, pp.
440
418
.
19.
Oxley
P. L. B.
,
1963
, “
Rate of Strain Effect in Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
85
, pp.
335
338
.
20.
Shaw
M. C.
, and
DeSalvo
G. J.
,
1970
, “
A New Approach to Plasticity and its Application to Blunt Two Dimensional Indenters
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
92
, pp.
472
479
.
21.
Sisson
T. R.
, and
Kegg
R. L.
,
1969
, “
An Explanation of Low-Speed Chatter Effects
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
91
, pp.
951
958
.
22.
Sutherland, J. W., 1988, “A Dynamic Model of the Cutting Force System in the End Milling Process,” Proc., ASME Symposium on Sensors and Controls for Manufacturing, PED-Vol. 33, pp. 53–62.
23.
Thomsen
E. G.
,
1966
, “
Application of the Mechanics of Plastic Deformation to Metal Cutting
,”
Annals of C.I.R.P.
, Vol.
14
, pp.
113
123
.
24.
Tlusty, J., and Polacek, M., 1963, “The Stability of the Machine Tool Against Self-Excited Vibrations in Machining,” ASME Prod. Engr. Res. Conference, Pittsburgh, pp. 454–465.
25.
Tobias
S. A.
, and
Fishwick
W.
,
1958
, “
The Chatter of Lathe Tools Under Orthogonal Cutting Conditions
,”
Transactions of the ASME
, Vol.
80
, pp.
1079
1088
.
26.
Wu
D. W.
,
1988
, “
Application of a Comprehensive Dynamic Cutting Force Model to Orthogonal Wave Generating Processes
,”
Int. Journal of Mechanical Sciences
, Vol.
30
, pp.
1
20
.
27.
Wu
D. W.
,
1989
, “
A New Approach of Formulating the Transfer Function for Dynamic Cutting Processes
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
111
, pp.
37
47
.
This content is only available via PDF.
You do not currently have access to this content.