CPIE-2016 Paper 27

DR B R AMBEDKAR NATIONAL INSTITUTE OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
ESTIMATION OF CUTTING FORCES IN CONVENTIONAL AND

ULTRASONIC-VIBRATION ASSISTED TURNING USING
INVERSE MODELLING
U.S. Dixit*1, V. Yadav1, V. Sharma2, P.M. Pandey2, A. Roy3, V.V. Silberschmidt3
1Departmentof Mechanical Engineering, Indian Institiute of Technology Guwahati, Assam,
India, 781 039
2Department of Mechanical Engineering, Indian Institiute of Technology Delhi, New Delhi,
India, 110 016

3Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University,
Loughborough, Leicestershire LE11 3TU, UK

*Corresponding author email: uday@iitg.ac.in
ABSTRACT
Turning is one of the most widely used machining processes. Recently ultrasonic-vibration
assisted turning has gained importance for machining difficult-to-machine materials. For
proper control and optimization of the process, modelling of the process is essential.
Modelling of the process requires introduction of friction as a function of process parameters
to estimate the cutting force. In the present work, an inverse method is proposed to evaluate
the velocity-dependent friction and fracture toughness based on a few tests in conventional
turning. The inverse methodology requires the data on cutting and feed forces at two
specified cutting speeds. The procedure employs direct analytical methods for conventional
as well as ultrasonic-vibration assisted turning. The method is verified with some
experimental data. The main cutting and feed force components are predicted accurately.
Thanks to its simplicity, the proposed procedure may find a good application in industrial
practice.
Keywords: Cutting forces, Ultrasonic-vibration assisted turning, Friction, Inverse method
1. INTRODUCTION
Ultrasonic-vibration assisted machining of metals was first carried out in late 1950s (Skelton,
1969; Brehl and Dow, 2008). Renewed interest in it started from 1990s for macro and micro
machining of difficult-to-machine materials. Literature contains studies on one-dimensional
as well as two-dimensional vibration assisted machining (VAM). In one-dimensional VAM,
the cutting tool undergoes harmonic motion in one direction (mostly in the direction of
cutting velocity with an amplitude less than 20m and frequency in the range 1040 kHz). In
two-dimensional VAM, the tool undergoes simultaneous harmonic motions in two directions,
thus moving in a circular or elliptic path. In VAM, the cutting forces are reduced and tool life
gets increased.
A brief review of VAM starting from 1990s is as follows. Morowaki et al. (1992)
explored ultraprecision diamond turning of sodalime glass by applying ultrasonic-vibration
with frequency of 40 kHz in the main cutting direction. A very good surface finish (0.03m
Rmax) was obtained. Babitsky et al. (2003) developed an autoresonant ultrasonic vibrations
assisted turning (UAT) system and used it for turning of C263, Inconel 718 and mild steel.
Vibrations applied in the feed direction improved the surface finish up to 50%. Zhong and
Lin (2005, 2006) developed an ultrasonic vibration device to study the turning of
aluminumbased metal-matrix composite (MMC) reinforced with SiC particles. The authors
designed a small-size vibration device without using a booster to mount the piezoelectric
1
transducer. In their experimental study, they used vertical CNC machine and applied
ultrasonic vibration to a cutting tool.
Ahmed et al. (2007) carried out a comparative study of conventional turning (CT) and
ultrasonically-assisted turning (UAT) of Inconel 718 by combining experiments and the
finite-element method (FEM). They conducted the experiments in the frequency range 1030
kHz and observed that the cutting forces reduced up to by 47% as compared to conventional
turning. The tangential vibration provided lower cutting forces as compared to radial
vibration in ultrasonically-assisted turning. Chen et al. (2008) performed experimental study
of CT and UAT of W-Fe-Ni alloy. A reduction in surface roughness was observed in UAT.
Hsu et al. (2008) carried out experiments on combined ultrasonically-assisted turning and hot
turning of Inconel 718 and used Taguchi method to study the influence of various machining
parameters. Nath and Rahman (2008) studied UAT experimentally and theoretically. They
analysed the effect of the tool-workpiece contact ratio in UAT. This ratio is defined as the
ratio between the tool-workpiece contact time during a single cycle and the total cycle time
period. When the tool workpiece contact ratio decreased, the cutting time of tool decreased.
As a result lower average cutting forces and increased tool life with high accuracy of
machining were obtained in UAT. Jiao et al. (2011) carried out experimental study of both
ultrasonic-vibration assisted turning and conventional turning. They used quenched steel as
workpiece material and found that surface-finish characteristics in ultrasonically-assisted
turning were better than those in conventional turning at low cutting speeds. Muhammad et
al. (2012a) analyzed the tangential component of the cutting force in the UAT process using
FEM based commercial software MSC, Marc/Mentat. The results of both CT and UAT
obtained with FEM were compared with experiments. The parametric study of the UAT
process at different levels of amplitude and frequency of the tool was also carried out and it
was found that the cutting force decreased with the increasing amplitude or frequency.
Jamshidi and Nategh (2013) performed an experimental study of conventional turning
and ultrasonic turning using Al 6061 as a work piece material. Reduction in the normal and
friction forces at the tool-chip interface was found to be 1982% and 2476%, respectively.
The coefficient of friction in the UAT process at the tool-chip interface was assessed as about
39% higher as compared to the CT process. Muhammad et al. (2014) studied the cutting
force, temperature and surface roughness of a workpiece machined at three different
processes viz., conventional turning (CT), hot conventional turning (HCT) and hot ultrasonic
assisted turning (HUAT). They observed a substantial reduction (about 95%) in tangential
and radial components of the cutting force in HUAT as compared to CT. The reduction in
cutting forces was mainly attributed to the decreased yield strength of the workpiece at
elevated temperatures. Further, a significant reduction in surface roughness in HUAT and
HCT was obtained as compared to CT.
In the present work, an inverse method is proposed for assessing the averaged cutting
force in CT and UAT processes considering the tool vibration in the cutting direction only.
The methodology requires estimation of the main cutting force and the feed force at two
specified cutting speeds in conventional turning. The validity of the inversely estimated
coefficient of friction and fracture toughness of the material are tested with experimental data
for CT and UAT.
Organization of the paper is as follows. Section 2 presents a direct analytical model to
determine the cutting forces in the CT and UAT processes. The parametric study is presented
in Section 3 considering the CT process. Section 4 introduces the inverse methodology.
Section 5 discusses the results of inverse modelling. Section 6 concludes the paper.
2
2. DIRECT MODEL
Estimation of cutting forces is the most important task for design, control and optimization of
a turning process. An efficient computational mathematical model is required for quick
estimation of cutting forces at different process parameters in turning. Figure 1 shows a
schematic view of orthogonal UAT turning, when the cutting tool is fully engaged with the
work material. The figure shows together with an assumed primary shear zone (domain
TUQRSPT), directions of cutting and tool vibration, normal rake angle and geometric
parameters. The following assumptions were made to simplify the analysis for determining
the forces in the present study:
The workpiece material is homogeneous, isotropic and incompressible.
During the engagement of the cutting tool with the work material, the velocity, shear
strain-rate and shear strain remains constant along the x-direction shown in Fig. 1.
It is possible to find out the main cutting force and the feed force in oblique cutting based
on orthogonal cutting analysis if the inclination angle is small. The rake angle is taken as
normal rake angle.
Figure 1. Schematic of orthogonal UAT process
As shown in Fig. 1, following Tounsi et al. (2002), the primary shear zone was divided by
main shear plane PQ (y = khs), where hs is the thickness of the primary shear zone and k < 1.
The primary shear zone is modelled as a shear band of constant thickness. The similar
assumptions were made by several researchers (Shaw, 1984; Li et al., 2011). In Fig. 1, RS
and TU planes depict the beginning and end of the primary shear zone, respectively. The
maximum shear strain-rate occurs at the plane PQ. Subsection 2.1 presents the mathematical
model for conventional turning, while modelling of ultrasonically-assisted turning is
presented in Subsection 2.2.
2.1 Estimation of cutting and feed forces in conventional turning process

In the present work, the expression for the cutting force is taken from Atkins (2003). Atkins
(2003) derived the expression for the cutting force based on modern ductile fracture
mechanics considering the following three energies energy for plastic deformation along
the shear plane, energy required to overcome friction at the tool-chip interface, energy
required to form a new (cut) surface. The expression for the cutting force based on the total
work is obtained as
cos n R cos n sin
Fc wt0 1 ,
sin cos n
(1)
t0 cos n
3
where w is the width of cut, t0 is the uncut chip thickness, is the shear yield stress, is the
friction angle, n is the normal rake angle, is the shear angle and R is the specific work of
surface formation (fracture toughness). The uncut chip thickness and width are f cos and
d/cos, respectively where is the side cutting edge angle in the ASA system, f is the feed
and d is the depth of cut. The friction angle () is given by
tan 1 , (2)
where is the coefficient of friction.
In the present work, the averaged coefficient of friction was introduced as a function of a
chip velocity (Dudzinski and Molinari, 1997; Li et al., 2011) by the following expression:
f 0 Vc , (3)
p
where f0 and p are the friction parameters and Vc is the chip velocity given by
Vc Vr , (4)
where r is the cutting ratio calculated as
sin
r
cos n
. (5)
The feed force ( F f ) is given by

Ff Fc tan n cos . (6)
The force due to friction on the rake face was calculated as (Ghosh and Malik, 2010)
F Fc sin n Fc tan n cos n . (7)
The shear yield stress () can be obtained from the Johnson-Cook model (Dixit and Dixit,
2015) as
1
A B 1 C ln 1 T T ,
n T Ta
m
(8)
3 0
m a

where A, B, C, n and m are material constants, is the strain, is the strain-rate, 0 is the

reference strain-rate, Tm is the melting temperature, Ta is the ambient temperature and T is the
process temperature. In Equation (1), was taken as the average shear yield stress (a)
calculated as

max
a 0
, (9)
max
where the maximum equivalent strain is calculated assuming the von Mises criterion as
follows:

max , (10)
3
where is the maximum shear given by
cos n

cos n sin
. (11)
Equation (9) is evaluated numerically by using two-point Gauss quadrature; a procedure

employed by Kalidasan et al. (2016) was used. Kalidasan et al. (2016) calculated the average
shear yield stress as
1 2
a , (12)
2
where
4
max 1 1
1 1 , 2 max 1 . (13)
2 3 2 3
In Equation (8), the expression of the strain-rate ( ) is taken as (Li et al., 2011)
V q 1 cos n

hs cos n
. (14)
where V is the cutting speed, q is the constant parameter dependent on cutting velocity and hs
is the primary-shear-zone thickness. The average temperature of the workpiece is calculated
in the following manner. The fraction of heat conducted to the workpiece is (Ghosh and
Malik, 2010)
27.5
pwp 0.15 ln , (15)
TN tan
where TN refers to the Thermal Number given by
cVt0
TN , (16)
k
where c is the heat capacity of the material and k its thermal conductivity. The average
temperature in K of the workpiece at the shear zone can be obtained as (Ghosh and Malik,
2010)
T
1 pwp Wp 273.15, (17)
cVt0 w
where w is the width of the cut and Wp is the rate of heat generation due to plastic
deformation given by
Wp Fc Fr V . (18)
A methodology described by Kalidasan et al. (2016) was employed to calculate the cutting
and feed forces. The cutting and feed forces were calculated iteratively till the assumed and
obtained temperatures did not differ significantly. The cutting force was minimized with
respect to shear angle () using a one-dimensional optimization technique.
2.2 Estimation of cutting and feed forces in UAT process

In this subsection, the expression for average cutting and feed forces are expressed for the
UAT process based on the cutting force predicted for conventional turning (already discussed
in Section 2.1). A procedure for determining the cutting forces for the UAT process is similar
to that in Godara (2016). For the sake of completeness, it is briefly presented as below.
The position of the tool tip is defined as (Brehl and Dow, 2008)
xtool a sin t , (19)
where t is the time, a is the amplitude and is the circular frequency of the ultrasonic tool,
which can be written as
2 f , (20)
where f is the frequency of the vibrating tool.
The velocity of the tool (V) is obtained after differentiating Eq. (19) with respect to t:
V a cos t . (21)
The relative velocity (Vt) between the tool and the work-piece is obtained by superimposing
the velocity of the work-piece and tool such as
Vt V acos t , (22)
where V is the velocity of the work-piece.
5
Figure 2 shows the relative velocity between the tool and the work-piece with time. The
separation of tool rake face and work-piece takes place at time t1. At time t2 the tool and the
work-piece starts moving towards each other. At time t3, the uncut material and the tool rake
face come into contact and at time t4 one cycle of the process is completed. The procedure of
cutting is a cyclic process, in which contact between the tool and the work piece is lost for
some time.
Figure 2. Typical plot of tool work-piece relative velocity vs. time

Here, time t1 indicates separation of the tools rake face and the work-piece, which is
evaluated from Eq. (22). It is assumed that at time t1, the relative cutting speed equals to zero,
therefore Eq. (22) provides
V
cos 1
t a . (23)
1

The relative distance travelled by the tool and the work-piece between time t1 and t3 is
zero. Therefore, t3 is calculated as follows
V
t3
t dt 0. (24)
t1
Substituting Eq. (22) into Eq. (24) and after integrating with respect to t, we get
V t3 t1 a sin t3 sin t1 0. (25)
Thus, the value of t3 is calculated by solving Eq. (25). At time t4 a cutting cycle has been
completed. Therefore, t4 = T+t1, where T is the time period.
In UAT, the relative velocity varying with time, therefore, the cutting and feed forces are
obtained as
1 4
FcUAT Fc v dt ,
t
(26)
T t3
and
1 4
FUAT F v dt .
t
(27)
T t3
where Fc(v) and F(v) are the cutting and feed forces as the functions of cutting velocity in
conventional turning, respectively.
6
3. RESULTS FROM DIRECT MODEL

The parametric study was carried out to obtain the cutting and feed forces for different levels
of primary-shear-zone thickness (hs), a constant parameter dependent on cutting velocity (q),
friction parameters (f0) and (p). Earlier researchers (Dudzinski and Molinari, 1997; Li et al.,
2011) considered the numerical values of hs, q, f0 and p based on empirical modelling or
experiments; the prediction of the cutting forces in turning process depends upon the
accuracy of these parameters. In this work, a parametric study is presented to observe the
influence of hs, q, f0 and p on cutting and feed forces. The cutting and feed forces were
calculated at different cutting velocity with different hs, q, f0 and p keeping other machining
process parameters constant. The workpiece material was titanium alloy (Ti-6246) with the
following parameters of Johnson-Cook model (Muhammad et al., 20012a): A=1657 MPa,
B=402 MPa, C=0.0054, n=0.218, m=0.8034. The reference strain-rate ( 0 ) was 1 s1, melting
temperature of the workpiece material (Tm) was 1898 K and ambient temperature (Ta) was
298 K. The thermal conductivity of the workpiece material (k) was 12 W/mK, specific heat of
the material (cp) was 500 J/kgK and the density of the material () was 4540 kg/m3. The
fracture toughness R was taken as 220 kJ/m2. The normal rake angle of the cutting tool was
taken as 6 and side cutting edge angle was 0.
Figure 3 shows the dependency of cutting and feed forces on primary-shear-zone
thickness (hs). It is observed that as hs was increased from 25 m to 250 m, the cutting force
decreased by 0.33% and feed force decreases by 0.46% at cutting speed of 30 m/min.
Similarly, when hs was decreased from 25 m to 0.25 m, the cutting forces increased by
1.26% and feed force by 1.08%. At other levels of cutting speed the forces were also not
much sensitive to thickness of the shear zone. Hence, it is appropriate to take a shear zone
thickness of 25 m, a value endorsed by several researchers (Shaw, 2005).
Figure 3. Effect of thickness of the primary shear zone (hs) on (a) cutting force and (b) feed
force at different cutting velocities
Figure 4 shows the effect of the speed-dependent-parameter q on the cutting and feed
forces. Li et al. (2011) suggested q=3 for low cutting speed and q=7 for high cutting speed.
However, its significant influence on the forces is not observed and it is considered
appropriate to take it as 5 for all the entire studied range of cutting speeds.
7
Figure 4. Effect of cutting-speed-dependent parameter q on (a) cutting force and (b) feed
force at different cutting velocities
Figure 5. Effect of friction parameter (f0) on (a) cutting force and (b) feed force at different
cutting velocities
In contrast, the friction parameter f0 had a significant effect on the cutting and feed forces
(Fig. 5). The variation of cutting and feed forces with cutting velocity follows a different
pattern, which is good for inverse analysis. Both the main cutting force and the feed force can
be used effectively.
The influence of another friction parameter (p) on the cutting and feed force at different
cutting speeds is presented in Fig. 6. The variation of cutting and feed forces with p follows a
8
different pattern than that for f0; this can be ascertained by comparing Fig. 5 with Fig. 6. It is
a desirable feature for inverse analysis, guaranteeing a unique solution.
Based on the parametric study, it was observed that the cutting forces were not very
sensitive to hs and q. Hence, in this work only the friction parameters and fracture toughness
are determined with the inverse method. In the subsequent section, an inverse methodology is
discussed to estimate f0, p and R based on measurements of cutting and feed forces.
Figure 6. Effect of friction parameter (p) on (a) cutting force and (b) feed force at different
cutting velocities
4. INVERSE MODELLING
The methodology for finding out the friction parameters and fracture toughness based on the
measurement of cutting and feed forces is as follows:
Step 1: Determine the ratios of feed force and cutting force at the lowest and highest cutting
speeds. Use Equations (6) and (2) to determine the coefficients of friction, 1 and 2, at these
speeds.
Step 2: With the known coefficients of friction at two cutting speeds, obtain the cutting force
for different values of fracture toughness R. The value of R that minimizes the error between
the estimated and measured cutting forces is considered as the true fracture toughness. In this
work, a one-dimensional search using a bisection method (Deb, 1998) was carried out to
minimize the error.
Step 3: Considering the velocity-dependent friction parameters f0 and p, Step 1 provides
1 f 0 Vc (28)
p
and
2 f 0 Vc . (29)
p
Dividing Eq. (29) by (28)

2 Vc 2
p
. (30)
1 Vc1
From Equation (30),
9
ln 2 / 1
p
ln Vc 2 / Vc1
(31)
The value of p is substituted in Eq. (28) or Eq. (29) to obtain the friction parameter f0.
5. RESULTS AND DISCUSSION

In this section, validation of the inversely estimated friction in the CT and UAT process is
carried out. Subsection 5.1 presents the validation of cutting force at different amplitudes and
frequencies in UAT for known friction. Subsection 5.2 presents the validation of the inverse
methodology considering the CT process.
5.1 Results for cutting forces in CT and UAT processes of Ti-6246

To validate the proposed procedure, a series of numerical experiments was conducted. The
workpiece material was the titanium alloy (Ti-6246). The chosen depth of cut (d) was 0.3
mm, uncut chip thickness (t0) was 0.1 mm, the rake angle (n) was 15 and the side cutting
edge angle () was 0. These input data were taken from Muhammad et al. (2012a). The
primary-shear-zone thickness (hs) was 0.025 mm and q=5. Muhammad et al. (2012a)
considered the fixed coefficient of friction of 0.5 at cutting speed of 10 m/min in their
simulations. Due to a lack of data for other levels of cutting speed, the f0 was taken as 0.489
and p = 0.019 based on the typical values in the literature. This corresponds to a coefficient
of friction of 0.5 at cutting speed of 10 m/min. The cutting ratio (r) was 0.518 for the
corresponding parameters. The inversely obtained value of R was 220 kJ/m2. The cutting
force obtained with the inverse model (using inversely estimated f0 and p) was compared with
those measured by Muhammad et al. (2012a) in CT as shown in Table 1.
Table 1. Validation of inverse estimation of friction with the experimental results of

Muhammad et al. (2012a) for UAT process (t0 = 0.1 mm, d = 0.3 mm, V = 10 m/min, n =
15, hs = 0.025 mm, q = 5, f0 = 0.489, p = 0.019)
Processes Cutting force (N) %
Inverse model Expt. (Muhammad et al., 2012a) error
CT process 119.23 119.12 0.09
UAT process 34.75 37.86 8.21
(f = 20 kHz and a = 8m)
The validity of the inversely estimated cutting force was tested for UAT with frequency f
= 20 kHz and amplitude a = 8 m of the vibrating tool. As seen from Table 1, the average
cutting force in UAT is in close agreement with its experimentally measured cutting force
magnitude. Thus, the friction and fracture toughness R in conventional turning, obtained with
the inverse method, can be used in UAT process.
Muhammad et al. (2012a) simulated the cutting force at different amplitudes and
frequencies using commercial software MSC Marc/Mental. Figure 7 compares the cutting
force, estimated with inverse methodology at different amplitudes with the data from
Muhammad et al. (2012a) for constant frequency (f = 20 kHz). It is observed that the cutting
force matches the results of Muhammad et al. (2012a) at higher amplitudes whereas at low
amplitudes the results of the inverse model differ by 25.8 %. The cutting force estimated with
the inverse model were also compared with the results of Muhammad et al. (2012a) at
different frequencies of the vibrating tool for constant amplitude (a = 8m) (Fig. 8). It was
found that the levels of cutting forces obtained with the inverse method were in good
agreement for different frequencies. The maximum deviation in the cutting force level was
less than 3% when compared with the results of Muhammad et al. (2012a).
10
Figure 7. Validation of cutting force obtained using inverse method with simulation results of
Muhammad et al. (2012a) at different vibration amplitudes
Figure 8. Validation of cutting force obtained using inverse method with the simulation
results of Muhammad et al. (2012a) at different vibration frequencies
The character of variation of the cutting forces with cutting velocity for the CT and UAT
process was also studied for the parameters obtained with inverse method. A significant
reduction in the average cutting force in UAT was observed as compared to CT for the same
cutting conditions. The similar observation was also reported by Muhammad et al. (2012b);
however, the workpiece material and the cutting conditions were different in that study. It is
seen from Fig. 9 that at cutting velocity of 10 m/min, the cutting force reduced by 71.4% in
UAT as compared to CT. The average cutting force increased with the increasing cutting
velocity in UAT, whereas it decreased in CT as expected. The cutting force in UAT reached
the same level of cutting force in CT at cutting velocity of 60 m/min.
11
Figure 9. Variation of cutting force with different cutting velocity in CT and UAT processes
obtained using inverse method
To study the variation in the cutting and feed forces for both CT and UAT processes, two
different machining process parameters viz., depth of cut and feed were considered; Table 2
shows that the cutting and feed forces increased linearly with the depth of cut for both cutting
techniques. The similar trend was also observed by Muhammad et al. (2012b) for the
workpiece material Ti-1533.
Table 3 shows the variation of cutting and feed forces in CT and UAT process with
different feeds. Additionally, the feed effect on the cutting force was studied for CT and
UAT. It was found that as feed increased from 0.1 to 0.2 mm/rev, the cutting force increased
by 58.2% in CT and 52.9% in UAT whereas feed force grew by 58% in CT and 55% in UAT.
However, if the feed is increased further from 0.2 to 0.3 mm/rev, the rate of increase of the
cutting and feed forces reduced in CT and UAT both process. Thus, the relation between feed
and cutting forces was non-linear.
Table 2. Cutting and feed forces for different depth of cut in CT and UAT processes
(t0 = 0.1 mm, V = 10 m/min, n = 15, hs = 0.025 mm, q = 5, f0 = 0.489, p = 0.019)
Depth of cut, Cutting force (N) Feed force (N)
d (mm) CT UAT CT UAT
0.1 39.07 10.35 24.39 6.91
0.2 78.14 20.29 48.79 14.62
0.3 119.28 34.21 74.51 19.45
0.4 156.27 39.88 97.56 24.26
0.5 195.34 48.05 121.96 35.58
For UAT process: f = 20 kHz and a = 8m
Table 3. Cutting and feed forces for different feeds in CT and UAT processes
(d = 0.3 mm, V = 10 m/min, n = 15, hs = 0.025 mm, q = 5, f0 = 0.489, p = 0.019)
Feed Cutting force (N) Feed force (N)
fr (mm/rev) CT UAT CT UAT
0.1 119.28 34.21 74.51 19.45
0.2 188.72 52.32 117.82 30.18
0.3 258.45 66.14 161.36 39.88
For UAT process: f = 20 kHz and a = 8m
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5.2 Validation of inverse methodology for CT process

In this section, the validation of inversely estimated the friction parameters obtained with the
inverse method for different cutting velocities is carried out. The inverse methodology
requires the cutting force measurement at two specified cutting velocity. Based on these data,
inverse estimation was carried out to determine the friction parameters f0 and p for the CT
process. Recently, Sharma and Pandey (2016) conducted an experimental study to measure
the cutting and feed forces at different cutting velocities in turning with hybrid textured self-
lubricating cutting inserts. The workpiece material was 4340 hardened steel. The constants of
the Johnson-Cook model were as follows (Jaspers and Dautzenberg., 2002): A=2100 MPa,
B=1750 MPa, C=0.0028, n=0.65, m=0.75. The reference strain-rate ( 0 ) was 7500 s1,
melting temperature of the workpiece material (Tm) was 1783 K and ambient temperature (Ta)
was 298 K. The thermal conductivity of the workpiece material (k) was 38 W/mK, specific
heat of the material (cp) was 477 J/kgK and its density () was 7830 kg/m3.
To implement the inverse analysis, the cutting force and feed force at cutting velocities 30
and 90 m/min were used. The methodology discussed in Section 3 was employed to assess
the friction parameters f0, p and R. It should be mentioned that the cutting and feed forces
obtained from the direct model were underestimated compared with the experimental values.
The value of R cannot be increased significantly; based on the results presented by Atkins
(2003), the value of R for this material cannot be greater than 20 kJ/m2. Hence, R was fixed at
this value and a scaling factor k multiplied was used to obtain the cutting and feed forces to
match the experimental results of Sharma and Pandey (2016). The purpose of introducing the
scaling factor, k was to compensate the error presents due to the workpiece material and/or
instrumental error during experiments. The value of k was defined as 1.43. The depth of cut
(d) was 0.2 mm, uncut chip thickness (t0) was 0.2 mm, rake angle (n) was 6, the side
cutting edge angle was 5, primary shear zone thickness (hs) was 0.025 mm and q= 5.
The friction parameters obtained from the inverse estimation were as follows: f0 = 0.314
and p = 0.224. The validity of these parameters was tested for CT at different cutting
velocities by comparing the cutting force and feed force. Figure 10 shows these comparisons
for different cutting velocities at inversely estimated parameters for conventional turning. The
predictions are in close agreement with the averaged experimental values of the cutting and
feed forces, with a difference of 2.4% .
Figure 9. Comparison of (a) cutting force and (b) feed force obtained using inverse method
with the experimental results of Sharma and Pandey (2016) at different cutting speeds
13
6. CONCLUSIONS
In the presented work, an inverse methodology was proposed to determine the friction and
fracture toughness in order to estimate the cutting and feed forces in conventional and
ultrasonic-vibration assisted turning. The methodology requires the measurement of the
cutting forces at two specified cutting speeds in conventional turning. It was found that the
inverse model provides a reasonable accuracy in determining the levels of cutting forces for
both CT and UAT processes. Hence, the proposed inverse methodology can be implemented
in the industrial practice for the online estimation of cutting forces in turning. The future
work aims at carrying out more experiments for various materials. Whether the fracture
toughness obtained is the real specific work of surface formation or is merely parameter of
the methodology needs also to be investigated. Finite-element analysis coupled with a large
number of experimental data can underpin clarification of these matters.
ACKNOWLEDGEMENT
The financial support offered by the DST (India)-EPSRC (UK) sponsored project entitled
MAST: Modeling of Advanced Materials for Simulation of Transformative Manufacturing
Processes (Grant identification: DST/RC-UK/14-AM/2012) is gratefully acknowledged.
REFERENCES
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DR B R AMBEDKAR NATIONAL INSTITUTE OF TECHNOLOGY JALANDHAR-144011, INDIA

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

ESTIMATION OF CUTTING FORCES IN CONVENTIONAL AND

India, 110 016

Loughborough, Leicestershire LE11 3TU, UK

Figure 1. Schematic of orthogonal UAT process

2.1 Estimation of cutting and feed forces in conventional turning process

The feed force ( F f ) is given by

Equation (9) is evaluated numerically by using two-point Gauss quadrature; a procedure

2.2 Estimation of cutting and feed forces in UAT process

Figure 2. Typical plot of tool work-piece relative velocity vs. time

3. RESULTS FROM DIRECT MODEL

Dividing Eq. (29) by (28)

5. RESULTS AND DISCUSSION

5.1 Results for cutting forces in CT and UAT processes of Ti-6246

Table 1. Validation of inverse estimation of friction with the experimental results of

5.2 Validation of inverse methodology for CT process

and high temperature-aided cutting. Journal of Materials Processing Technology, 198,

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