A model to calibrate and predict forces in machining with honed cutting tools or inserts

This paper describes a mechanistic approach towards modeling the effects on machining forces of the edge hone commonly ground on machining tools and tool inserts. This approach proposes that the ratio of the shearing to ploughing forces would remain identical for tools with different honed radii, machining under identical conditions of chip thickness to edge hone radius ratios and cutting velocity. This concept allows a very simple and new calibration technique toward separating out the effects of tool and machining parameters that influence the force coefficients in machining without a need for any additional parameters. The model has been presently developed for orthogonal cutting and its validation using a tube turning process on gray cast iron with straight edged inserts has shown very promising results. Continued research is being performed to evaluate the applicability of the model for more complex machining operations. (C) 2006 Elsevier Ltd. All rights reserved.