Distribution of unit forces on the tool edge rounding in the case of finishing turning

Abstract

An experimental investigation was conducted to determine the effects of tool cutting edge geometry on the cutting forces in finish turning, where the applied feed and depth of cut are small and often comparable with the tool edge radius. If a tool with large tool edge radius is used in finish turning, the ploughing effect begins to determine the machined surface. This paper presents the results of analytical considerations concerning the unit forces on a cutting edge. The aim of this paper is to indicate possibilities of modelling the unit forces and stress distribution based on cutting resistance. The forces calculated in the feed and cutting speed directions were projected onto the tangential and normal directions of the rounded cutting edge surface. An important assumption in all the considerations was that the thermo-mechanical properties of the materials used remained constant. The minimum thickness of cut was defined, and some characteristic points were identified dividing the cutting zone into three subregions: where a chip is formed, where the machined surface is formed and an unstable region. © 2011 Springer-Verlag.