Improvement of cutting forces modeling based on oriented cutting tests

In order to predict the characteristics of the machined part, such as geometry, surface roughness and fatigue or corrosion resistance, the cutting forces values should be known as precisely as possible. The edge discretisation methodology can be used to model the three components of the cutting forces. The results are generally considered as suitable, even if the considered cutting operation is complex, because the geometry is well described. Usually, the local cutting forces model is identified from orthogonal or oblique cutting tests and the local contributions are assumed to be independent of the orientation of the elementary edge in the reference plane P-r. However, when turning in the tool nose or with round inserts, the tool cutting edge angle K-r (or Side Cutting Edge Angle) evolves along the active cutting edge and the values of this angle are very small compared to that of 90 degrees used in orthogonal/oblique cutting. For this study, a new elementary cutting operation, called "oriented cutting", has been tested. In this configuration, the active cutting edge is rectilinear, without inclination, but oriented by an angle K-r different from 90 degrees. In addition, cylindrical turning tests have been done. The measurements, performed in pure copper, show an influence of the tool cutting edge angle on the cutting forces. An interaction between K-r and the workpiece radius is also highlighted. (C) 2013 The Authors. Published by Elsevier B.V.