Applying extended Oxley’s machining theory and particle swarm optimization to model machining forces

Abstract

Oxley’s parallel-sided thick zone model is the mostly used analytical approach to simulate the cutting process. In order to apply this approach, the flow stress needs to be calculated as a function of the strain, the strain rate, and the temperature. Among the various models that describe the materials’ plastic behavior, the Johnson-Cook (JC) equation has been extensively used. Therefore, the prediction of the JC parameters for a given material is a laborious and costly task. Using the extended Oxley’s theory and experimental results, the coefficients can be found in an inverse procedure. This optimization process can be solved using particle swarm optimization (PSO). Hence, this work deals with the prediction and analysis of the JC equation parameters obtained by an inverse procedure applying PSO. The simulated parameters are used to calculate the machining forces. The results show that the presented approach can predict the cutting and thrust forces very well.