3 Jurnal ScienceDirect tentang:

Turning Machine
Anggie Nindia Clara Simatupang
2013-043-196
Modeling of Cutting Force
Distribution on Tool Edge
in Turning Process
Guicai Zhang and Changsheng Guo
Procedia Manufacturing
Volume 1, 2015, Pages 454–465
 Abstract
Machining process models can be used to predict cutting force/power and
further optimize the process parameters. In this work, a mechanistic cutting force
model for turning processes is developed. In order to accurately predict cutting forces,
the cutting tool edge is discretized and an approach for calculating the chip load
corresponding to each discretized edge segment is developed. Approach for
calculating effective tool angles is also developed considering effects of the tool corner
radius and the change of feed direction. By using the yield shear stress of the work
material, the friction angle between work and tool material, the chip load and the
effective tool angles for each tool edge segment, the distributions of the turning
forces and force intensity along the tool edge can be predicted. Turning cases of
straight turning, contour turning, taper turning and facing are tested and the model
outputs include the distributions of the instantaneous effective tool angles, chip load,
cutting force coefficients and force intensity. Test results for straight turning and
contour turning operations are analyzed to demonstrate the model capability. The
distributions of force and force intensity on tool edge provide useful information for
prediction of turning forces/power and potential further prediction of tool wear/life.

Keywords: Modeling, Cutting force, Turning process

 Introduction
With the ever-increasing applications to precision machining and the machining of
difficult-to-machine materials, it is more and more important to model turning process thus to
predict cutting forces and to optimize the process parameters.
Merchant pioneered the metal cutting mechanics for orthogonal cutting in about 70
years ago (Merchant, 1944). His work laid down a solid foundation for the theoretical modeling of
metal cutting thereafter. Most of the fundamental work in early stage was on orthogonal metal
cutting (Lee & Shaffer, 1951) (Palmer & Oxley, 1959). Results on orthogonal cutting can be easily
transformed to that of oblique cutting which is the basis of models for all practical machining
processes including turning. In the past twenty years, the modeling of turning processes attracted
more and more attention due to the motivation of reduction of machining cost and improving
product quality (Chandrasekharan, Kapoor, & DeVor, 1995) (Reddy, DeVor, & Kapoor, 2001) (Song,
2006) (Kaymakci, 2009) (Gencoglu, 2011). In most of the published work, the chip load was
divided into several zones and one or more of the zones were discretized (Endres, 1990; Budak,
2007; Altintas, 2012). For the cutting force coefficient models, some researchers used empirical
model in which major factors such as rake angle, cutting speed and chip thickness was considered
and the coefficients for these factors were determined by cutting experiments (Reddy, DeVor, &
Kapoor, 2001). Some others used analytical models incorporating tool rake angle and inclination
angle, shear angle, friction angle between the tool and the chip, yield shear stress of the work
material, etc. (Altintas, 2012) (Song, 2006) (Kaymakci, 2009). There is no literature available on
investigating the distributions of cutting force and force intensity along the tool edge, although
this is useful for evaluating or modeling the detailed tool wear status.
 Introduction (2)
Major factors affecting cutting forces include tool/work material properties, cutting
process parameters (chip load and cutting speed), and tool geometry. Effective tool angles
change with the changing of the feed direction and they also change drastically near the tool
corner. In precision machining or finishing machining, the depth of cut is small and the tool
corner part may take most of the work. It is desirable to model the turning process for predicting
the distributions of effective tool angles and the chip load along the tool edge, and thus to
accurately predict the cutting forces.
In this work, a mechanistic cutting force model for turning processes is developed. In
order to accurately predict cutting forces, the cutting tool edge is discretized and an approach for
calculating the chip load corresponding to each discretized edge segment is developed. Approach
for calculating distributions of the effective tool angles is also developed considering effects of
the tool corner radius and the change of feed direction. By using the yield shear stress of the
work material, the friction angle between the work and the tool material, the chip load
distribution and the effective tool angles for each tool edge segment, the distributions of the
cutting forces and force intensity along the tool edge was predicted. Turning cases of straight
turning, contour turning, taper turning and facing are tested. The distributions of the effective
tool angles and chip load, and the predicted force and force intensity distributions are analyzed.
The distributions of force intensity on tool edge provide useful information for prediction of
turning forces/power, optimization of cutting parameters and potential prediction of tool
wear/life.
 Turning Model Development
The primary purpose of modeling cutting process is
to predict cutting forces. With the knowledge of cutting
forces, the power consumption, cutting tool properties
and metal part quality can be estimated. The cutting
process parameters can also be optimized based the
prediction of cutting forces.
The measured cutting forces should include both
the forces due to metal shearing and a tertiary
deformation process “ploughing” or “rubbing” at the
flank of the cutting edge. It is convenient to express the
cutting forces as two parts: metal shear force part and
edge force part (Altintas, 2012).
 Turning Model Development (2)
(1)

where Ft, Ff, Fr are the tangential, feed and radial forces respectively and Ktc, Kfc, Krc are the
cutting force coefficients in the three corresponding directions, Kte, Kfe, Kre are the edge force
coefficients in the three directions respectively, and b is the width of cut (edge length) and h is
the uncut chip thickness.
As the edge force coefficients are purely determined by cutting experiments, the most
important part of the cutting process modeling is to model the metal shear force. And the shear
force modeling includes two aspects: chip load modeling and the cutting force coefficients
modeling. The chip load is determined by the uncut chip thickness and the width of cut (or the
feed rate and the depth of cut), the geometry and the orientation of the tool and the workpiece.
The modeling the cutting force coefficients is determined by the material properties of the
workpiece and the cutting tool, tool geometry, and the cutting speed. The modeling of the chip
load and the cutting force coefficients will be discussed in the following sections.
 Chip Load Model
The chip load model computes the instantaneous cutting area. The nominal
cutting area is determined by the uncut chip thickness and the width of cut (or the
feed rate and the depth of cut). The accurate computation of the cutting area is also
affected by other factors such as the geometry of the tool and the profile of the
workpiece, the varying instantaneous feed direction, etc. The uncut chip thickness is
not constant along the tool edge considering the curved tool edge around the tool
corner and nonlinear tool path (e.g., contour turning).
In order to accurately compute the cutting areas and the chip load
distribution along the working tool edge, the tool edge is discretized. Figure 1 shows
the approach of the edge discretization. After discretizing the working tool edge, the
chip load is divided into a series of subareas with the same dimension in radial
direction (dx) of the turning except the last one in the tool corner part (D), while the
axial dimensions of the subareas are the same (dy) for the straight edge part (AB) and
vary for the tool corner part (BCDE). In this work, the discretization length dy is 0.001
inch and dy is related to the feed rate and it changes with the location of the subareas
(dy is equal to the feed per revolution for the straight turning). With this discretization
level, the simulation time is usually several seconds for one turning step in a regular
laptop PC (e.g., DELL Latitude E6430).
Chip Load Model (2)
 Shear Force Model
For a given chip load,
the shearing
components of the
cutting forces are
determined by the
cutting force
coefficients. The cutting
force coefficients for
oblique cutting are
shown in Equation 2
(Armarego &
Uthaichaya, 1977)
(Altintas, 2012). They
are transformed from
orthogonal cutting
equations by using the
angles transformation
shown from Equation 3
to Equation 7.
Shear Force Model (2)
Turning Force Model
Case Studies and Results Analysis
 Case 1: Straight Turning
Figure 5 shows the distributions of the tool approach
angle, inclination angle, chip flow angle, normal rake angle,
normal friction angle and the normal shear angle for the
straight turning step (Step 1). In the figure, line segments AB
and BC correspond to the straight edge and the tool corner
part respectively. The turning point B is the tangential point
between the straight edge and the tool corner. It is shown that
for the straight turning operation, these angles are constant in
the straight edge part, while they vary within the tool corner
area. The normal friction angle and the normal shear angle
have a similar trend as the normal rake angle. For the straight
turning, the distributions of the tool angles for all workpiece
revolutions are coincident.
Case 1: Straight Turning (2)
 Case 1: Straight Turning (3)
Figure 6 shows the distributions of the uncut chip thickness for all the revolutions
in the first step(straight turning with sixty revolutions in total). The engaging length of the
tool edge increases with changing correspondingly. From the tenth to the fifty-ninth
revolution the thickness distributions are coincident. While the chip thickness for the last
revolution (the sixtieth) is significantly smaller than that of the other revolutions as the feed
amount is smaller than the nominal values when the tool reaches the end of the tool path.
Figure 7 shows the distributions of the cutting areas for all the revolutions in the
first step. From the tenth revolution (Rev 10-59), the area distributions become constant
(even). For the revolutions 10- 59, the trends of the area distributions are different from that
of the distributions of uncut chip thickness shown in Figure 6 as the area distribution is
constant while the thickness is varying in the tool corner part. Again, the area distribution for
the last revolution (Rev 60) is smaller than that of the other revolutions.
Case 1: Straight Turning (4)
 Case 2: Contour Turning
In contour turning, the effective tool angles are affected by not
only the tool edge profile but also the changing of the feed direction.
Figure 13 shows the distributions of the major tool angles for the
contour turning (Step 2). There are thirteen revolutions in total for the
whole second step. In order to depict the curves clearer, only data for
odd revolutions are shown in the figures. It is shown that for the
contour turning operation, these angles are constant in the straight
edge part at a time instance but they change with time due to the
nonlinear direction of the feed motion. For the tool corner part,
theeffective tool angles change with both the feed direction and the
positions on the tool corner (due to the change of the side cutting
edge angle). The length of the engaging tool edge changes (decreases
for this specific case) with time during the whole contour turning step
due to the change of the feed direction, as sh own in Figure 14.
Case 2: Contour Turning (2)
 Case 2: Contour Turning (3)
Figure 15 shows the distributions of the uncut chip thickness for the odd
revolutions in the second step (contour turning). It is seen that the distributions of the
uncut chip thickness are different for different revolutions due to the changing of the
feed direction. Similar to that of the straight turning case, the thickness of the last
revolution (Rev 13) is significantly smaller than that of other revolutions as the tool
reaches the end of the tool path in this step. Similar trend will be seen in the plots for
cutting areas and forces shown in the following paragraphs. As some lines are too
close to be distinguished, zoomed-in plots are added in some of the following figures.
Figure 16 shows the distributions of the cutting areas for the odd revolutions
in the Step 2. As the engaging length of the tool edge is changing from revolution to
revolution for the whole contour turning step, the area distributions are also changing
along the tool path. The normalized area distributions are shown in Figure 17. It is
seen that the uncut chip thickness and cutting areas for the last revolution of the step
are significantly smaller than that of other revolutions. Figure 18 shows the length
distributions of the discretized edge segments used for normalizing the cutting areas
(only a few selected revolutions, namely Rev 1, 5, 9, 13, are shown).
Case 2: Contour Turning (4)
 Case 2: Contour Turning (5)
Figure 19 shows the distributions of the tangential cutting
coefficients of the odd revolutions in the second step. It is seen that
the trend of the tangential coefficients is changing from the first to the
last revolution. The varying trend is due to the changing of the feed
direction. The trend of the cutting coefficients for the last revolution is
close to that of the straight turning shown in Figure 10, as the feed
direction of the last revolution in contour turning is close to that of the
straight turning.
Figure 20 and Figure 21 show the distributions of the
tangential cutting force and the force intensity for Step 2. Again only
the odd revolutions are shown for simplicity. The trend of the
tangential force for the last revolution (Rev 13) is similar to that of the
straight turning shown in Figure 11. And the trends of the force
intensity are similar to that of the normalized cutting areas.
Case 2: Contour Turning (6)
 Case 2: Contour Turning (7)

In this section, modeling results for two typical turning

operations (straight turning and contour turning) are analyzed to
demonstrate the model capability. The shear forces are determined
by the chip load and cutting coefficients. And the cutting force
coefficients are determined by the tool angles and the material
properties. As the major outputs, the distributions of the tool
angles, uncut chip thickness, chip load, and the cutting coefficients
are analyzed. The distributions of the tangential force and force
intensity along the tool edge will be useful for tool wear/life
evaluation and analysis.
 Conclusions
In this work, a mechanistic cutting force model for
turning processes is developed. The model identifies the
cutting area distribution, and computes the instantaneous
effective tool angles, cutting parameters, cutting forces, force
intensity and their distributions. The distribution of the force
intensity along the tool edge is a very important parameter as
it reflects the force load variation and load time history on the
tool edge. The variation of the force intensity distribution with
time/revolutions provides valuable information for thermal
modeling of turning process such as calculating heat flux and
cutting temperature distributions along cutting edge. The
combined force intensity and thermal results can be further
used for tool wear/life analysis and prediction, and turning
process optimization.
 References
Altintas, Y. (2012). Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, 2nd ed. New
York: Cambridge University Press.
Armarego, E. J., & Uthaichaya, M. (1977). A Mechanics of Cutting Approach for Force Prediction in Turning Operations. Journal of
Engineering Production, 1(1):1-18.
Chandrasekharan, V., Kapoor, S. G., & DeVor, R. E. (1995). A Mechanistic Approach to Predicting the Cutting Forces in Drilling: with
Application to Fiber-reinforced Composite Materials. Journal of Engineering for Industry, 117:559-570.
Endres, W. J. (1990). A Dynamic Model of the Cutting Force System in the Turning Process. Proc., Symp. on Monitoring and Cont.
for Mfg. Processes, ASME WAM, PED-44, (pp. 193-212).
Gencoglu, A. (2011). Physics Based Turning Process Simulation. Master's Thesis: The University of British Columbia, Vancouver,
Canada.
Kaymakci, M. (2009). Generalized Modeling of Metal Cutting Mechanics. Master’s thesis: The University of British Columbia,
Vancouver, Canada.
Lee, E. H., & Shaffer, B. W. (1951). Theory of Plasticity Applied to the Problem of Machining. Journal of Applied Mechanics, 18:405-
413.
Merchant, M. E. (1944). Basic Mechanics of the Metal Cutting Process. Journal of Applied Mechanics, 66:168-175.
Palmer, W. B., & Oxley, P. L. (1959). Mechanics of Orthogonal Machining. Proceedings of the Institution of Mechanical Engineers,
173(24):623–654.
Reddy, R. G., DeVor, R. E., & Kapoor, S. G. (2001). A Mechanistic Force Model for Combined Axial–Radial Contour Turning.
International Journal of Machine Tools & Manufacture, 41:1551-1572.
Song, W. (2006). Development of Predictive Force Models for Classical Orthogonal and Oblique Cutting and Turning Operations
Incorporating Tool Flank Wear Effects. PhD Thesis: Queensland University of Technology, Queensland, Australia.
Cutting forces during turning
with variabledepth of cut
M. Sadílek, J. Dubsk´y, Z. Sadílková,
Z. Poruba
 Summary
The purpose of this paper is to investigate the problems with
increasing the effi-ciency of turning cycles. This paper also describes
and suggests the possibility of using effectivestrategies and their
application in programming CNC turning centers. It proposes new
roughingturning cycles where variable depth of cut is applied.
Suggested roughing cycles with the use ofvariable depth of cut will
ensure increasing the durability of the cutting tool and the
efficiencyduring turning.The proposed research for the paper is an
experimental work — measuring cutting forcesand monitoring of the
tool wear on the cutting edge. It compares the turning where
standardroughing cycle is used and the turning where the proposed
roughing cycle with variable depthof cut is applied.

Keywords: Turning; Variable depth of cut; Cutting forces;CAD—CAM

systems
 Roughing tool path in turning
CAD/CAM systems produce the technological basis forcomputer-controlled production. For
standard programmingof rough turning tool paths online programing SFP — ShopFloor Programing is
commonly used. For specific program-ming of tool paths (non-linear tool path and cycles that arenot in
cycles at the workshop) it is appropriate to use CAMsystems (Hatala, 2007; Svetlik and Dobransky, 2005;
Sadíleket al., 2011).The conventional roughing cycles in turning, where a cut-ting tool performs constant
depth of cut, can be adapted andextended with the cycles when the tool cuts with variabledepth of cut.
The proposed roughing cycles are as follows:
• Tool paths ‘‘decreasing of engagement’’, see Fig. 2.
• Tool paths with creating conic surface, see Fig. 3.
• Tool paths with the use of nonlinear methods, see Fig. 4.
Fig. 1 shows commonly used roughing cycle. In Fig. 1 it ispossible to see a constant depth of
cut, which is used in thisroughing cycle. The machining process results in wear thatprevails in one point
of the cutting edge only.
During the roughing strategy — cut decrement, each chipremoval is performed with a
different depth of cut so a dif-ferent cutting part of the tool is under stress during eachcutting
operation. This method of machining can be time consuming due to more passes. This is compensated
for byincreased tool life, lower loading of the machine spindle andreduced machine noise. The depth of
cut is reduced whenthe final diameter is being approached. The maximum wearpoint is therefore
moved outwards from the cut, prolong-ing by doing so a longer cutting tool durability. This typeof
roughing cycle is already contained in some CAM sys-tems (for example Mastercam and Edge CAM).
Applicationof this feature when longer parts are turned is advan-tageous for the elimination of ever-
decreasing workpiecestiffness.
The cutting where a conical surface is formed starts withthe greatest depth of cut which
decreases in the feedingdirection, see Fig. 3. The second cut is programmed to beparallel with the
workpiece axis. This provides for efficientremoval of the conical surface formed in the previous
cut.Thanks to this strategy, the tool wear moves along the cut-ting edge from the maximum to minimum
depth of cut (apmax to apmin).
Roughing tool path in turning (2)
 Roughing tool path in turning (3)
The non-linear roughing cycle method also ensures thevariable
depth of cut. For example, the tool path’s wavyprofile (Fig. 4) will
achieve the same effect as the previousmethods. In the first cut and
the second cut, the machinedmaterial is on gradual increase and
decrease and a variabledepth of cut is thereby achieved. It is also
possible to shiftthe machined surface and, in doing so, change the
depth ofcut. However, this requires an advanced CAD/CAM
systemjoined with the CNC cutting machines.
 Experimental Work
Two strategies were used during longitudinal turning: conventional
method with constant depth of cut and turningwith the creating the conical
surface.
Within this experiment cutting machine was used: DMGMORI NLX
2500MC/700 with control system MitsubishiM730BM and with the spindle
power 18.5 kW. The work piecematerial was used cold-work tool steel 1.2379
which corre-sponds to the DIN X155CrVMo12 1 (ˇCSN 19 573) with
hardness23 HRC. Typical applications include punching and blank-ing dies.
Size of workpiece (flange) was external diameterØ D = 150 mm, length L = 450
mm. Cutting tool was externalradial turning tool DWLNR 2525 M08 (company
Sandvik) withcutting inserts: WNMG 080408 E-FM (company Pramet tools).
This tool is suitable for longitudinal medium roughing androughing. During
cutting, cutting fluid was not used. Thecutting conditions differed only in the
cut size and depthshape, see Table 1. Amount of material to be machined
(perunit time) is the same.
 Experimental Work (2)
The different depths of cut (stock removals) in
the inter-nal roughing cycle are shown in Fig. 5.
Here a gradualremoval of material from first tool
path to the last (nth) is shown. Total number of tool
paths (n) depends on the size of the work piece and
technological possibilities of insert aswell.
During machining components of cutting
forces and toolwear were measured. Conclusions of
tool wear results areshown below. Tool live of
strategy variable depth of cut wasincreased from
6.2 min to 8.3 min ( T = 2.3 min, this is about 20%)
(Fig. 6).
Experimental Work (3)
 Experimental Work (4)
Dynoware software (company Kistler) was used for the
measurement of cutting forces and subsequent analysis of the data
obtained. For further processing Excel was used. Three-component
piezoelectric dynamometer and connection with PC are shown in Figs.
7 and 8.
The direction of each axis of the dynamometer has been set as
shown in Fig. 8.
Fx component of cutting force acts perpendicular to the axis of
the workpiece — expressing radial (passive) component of cutting
force Fp. Fp greatly affects dimensional accuracy of machined surfaces,
the geometric deviations of shape and position and surface roughness
of the machined surface.
Fy component of cutting force acts tangentially — expressing
cutting component of cutting force Fc. Fc is the basis for determining
the limiting conditions in the choice of cutting parameters. Specifies
the required power and the total amount of heat in the cutting zone.
Fz component cutting force acts in the direction of feed— expressing
feed component of cutting force Ff. Ff is used in the dimensioning
traverse mechanisms.
Experimental Work (5)
 Cutting Forces during Turning
Fig. 9 shows the one tool pass during the strategy with
variable depth of cut when the depth of cut starts at a
minimum depth apmin= 1.5 mm and ends apmax= 2.5 mm.
This tool pass represents the total file measured data and is
intentionally selected for the size of the wear inserts (VBmax=
0.205 mm after ts = 2.4 min), which is in the region of steady-
state wear (2nd region of wear).
 Cutting Forces during Turning (2)
Strategy with variable ap has lower
resultant of the cutting forces and also has
lower cutting forces of all components, see Fig.
10. Fig. 10 also marked tool wear Vbmax
corresponding to the machine time.
 Cutting Forces during Turning (3)
The percentage comparison (cutting
forces) of both strategies is shown in Fig. 11.
Besides the first two minutes the new strategy
with a variable depth of cut is better.
 Cutting Forces during Turning (4)
From Table 2 machine time is evident, when there is a change
cutting force component ratio. Changing ratio of strategy constant ap is
earlier than the ratio of strategy variable ap. After a time ts = 4.8 min will
change the ratio. Dominant cutting component changes into a dominant feed
component. This can be explained by tool wear, which is in 3rd region
(accelerated wear region).
The ratio of the individual components of the cutting force is
determined primarily by technology of machining, cutting conditions,
geometry and material of the cutting tool(Antic et al., 2012; Cep et al., 2011,
2013; Neslusan et al.,2011).
Cutting Forces during Turning (5)
 Experimental results and discussion
Cutting forces while
turning with constant and
variable depth of cut
increases knowledge of the
practical implementation
of the proposed strategies
with variable depth of cut
to streamline production.
Strategy with variable
depth of cut has a
beneficial effect on the size
the cutting forces and
cutting forces and their
amplitude.
 References
Antic, A., et al., 2012. The influence of tool wear on the chip forming mechanism and
tool vibrations. Mater. Tehnol. 46 (3),279—285, ISSN 1580-2949.
ˇCep, R., et al., 2011. Cutting tool life tests of ceramic inserts for car engine sleeves.
Teh. Vjesn./Techn. Gaz. 18 (2), 203—209,06/2011, ISSN 1330-3651.
ˇCep, R., et al., 2013. Experimental testing of cutting inserts cutting ability. Teh.
Vjesn./Tech. Gaz. 20 (1), 21—26, 1/2013, ISSN 1330-3651.
Hatala, M., 2007. Simulation of Technological Process, 1st ed. FVTTU, Preˇsov, ISBN
978-80-8073-756-6, pp. 85.
Nesluˇsan, M., et al., 2011. Deformation after heat treatment and their influence on
cutting process. Teh. Vjesn./Tech. Gaz. 18 (4),601—608, ISSN 1330-3651.
Sadílek, M., et al., 2011. Aspects of using tool axis inclination angle .Stroj. Vestn. — J.
Mech. Eng. 57 (9), 681—688.
Sadílek, M., et al., 2013. Increasing tool life in turning with variable depth of cut.
Mater. Tehnol. 47 (2), 199—203, ISSN 1580-2949.
Svetlik, J., Dobransky, J.,2005. Discourse about best choice CAD/CAM system. In: New
Trends in Technology System Operation. Proceedings of the Seventh
conference with international participation. Technická Univerzita, Koˇsice,
ISBN 80-8073-382-1,pp. 90—92.
Modeling and prediction of cutting
forces during the turning of red
brass
(C23000) using ANN and regression
analysis
M. Hanief, M.F. Wani, M.S. Charoo
Mechanical Engineering Department,
National Institute of Technology, Srinagar,
Jammu & Kashmir 190006, India
 Abstract
The life of a cutting tool is greatly influenced by the forces acting on
it during a cutting operation. A machining operation is a complex process. It is
very difficult to develop a comprehensive model involving all the parameters.
The present study aims to develop a model to investigate the effects of
cutting parameters (speed, depth of cut and feed rate) on the cutting forces
during the turning operation of red brass (C23000) using high speed steel
(HSS) tool. The experimental results are based on full factorial design
methodology to increase the reliability and confidence limit of the data.
Artificial neural network and multiple regression approaches were used to
model the cutting forces on the basis of cutting parameters. In order to check
the adequacy of the regression model, analysis of variance (ANOVA) was
used. It was clear from the ANOVA that the regression model is capable to
predict the cutting forces with high accuracy. However, ANN model was found
to be more accurate than the regression model.

Keywords: ANN, Brass, Cutting forces, Regression, Turning