Knowledge of the cutting forces owing to a predictive model is very interesting with respect to the choice of a machine tool power, the cutting tools, the optimization of cutting conditions for a given machining operation or the control of the occurrence of vibrations. It could also be helpful in online wear monitoring during milling. As this technique is usually based on a limit level of the cutting forces, it could allow the number of long and expensive tests to be limited and the best tool geometry to obtain quasi-constant and low cutting forces, which lead to a reduced tool wear, and consequently, a better tool-life, to be found. The objective of this study is the prediction of the effects of the rake and helix angles on the cutting force variations, and to integrate it into a cutting relation. Tests were made on X38 CrMoV 5 (AISI H11) die and mould steel, with solid carbide milling cutters of various rake angles. A specific configuration has been used to create obliquity. Cutting forces were measured for various feed rates. The results have improved the cutting force model, making it possible to choose the optimal rake and helix angles in a particular machining operation.
International audienceIn order to predict the characteristics of the machined part, such as geometry, surface roughness and fatigue or corrosion resistance, the cutting forces values should be known as precisely as possible. The edge discretisation methodology can be used to model the three components of the cutting forces. The results are generally considered as suitable, even if the considered cutting operation is complex, because the geometry is well described. Usually, the local cutting forces model is identified from orthogonal or oblique cutting tests and the local contributions are assumed to be independent of the orientation of the elementary edge in the reference plane Pr. However, when turning in the tool nose or with round inserts, the tool cutting edge angle Kr (or Side Cutting Edge Angle) evolves along the active cutting edge and the values of this angle are very small compared to that of 90° used in orthogonal/oblique cutting. For this study, a new elementary cutting operation, called "oriented cutting", has been tested. In this configuration, the active cutting edge is rectilinear, without inclination, but oriented by an angle Kr different from 90°. In addition, cylindrical turning tests have been done. The measurements, performed in pure copper, show an influence of the tool cutting edge angle on the cutting forces. An interaction between Kr and the workpiece radius is also highlighted
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AbstractIn this paper, a review of work performed in the area of force modelling in metal cutting processes is presented. Past and present trends are described and criticised to compare their relevance with current requirements. Several approaches are reviewed, such as empirical, mechanistic and analytical models. The models' ability to predict forces, from rough machining to finish machining, is analysed.
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