The curved uncut chip thickness model: A general geometric model for mechanistic cutting force predictions

• Published in: International journal of machine tools & manufacture 2023-05, Vol.188, p.104019, Article 104019
• Main Authors: Hajdu, David, Astarloa, Asier, Kovacs, Istvan, Dombovari, Zoltan
• Format: Article
• Language: English
• Subjects: Curved uncut chip thickness; Cutting force; Nose radius
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2023.104019

The curved uncut chip thickness model is introduced to predict the cutting forces for general uncut chip geometries using the mechanistic approach. Classical geometric models assume that the cutting force is distributed along straight elementary sections of the uncut chip area, which has limited physical validity, but makes mathematical treatments easier for simple cases. The new model assumes that the flow of the material on the contact area of the tool is given by a continuous vector field, according to which the curved uncut chip thickness is measured. The cutting force is distributed along these paths, which leads to a mathematically unique and consistent solution for regular and complex cutting edge geometries. These curved paths can be generated by basic mechanical models, which mimic the more realistic motion of the chip segments along the rake face, without the need of explicit time-consuming cutting simulations. The presented computational procedure generalizes cutting force prediction based on geometric parameters, orthogonal cutting data and the orthogonal to oblique transformations only. The effectiveness of the model for various cutting edge geometries (e.g., thread turning inserts) under extreme cutting conditions is presented in case studies, laboratory and industrial experiments. [Display omitted] •The novel concept of the curved uncut chip thickness is introduced.•Cutting force is distributed along curved paths on the rake face of the tool.•The solution of the model is unique and free of inconsistency for complex geometries.•The method improves cutting force predictions at high feeds and extreme conditions.