Analytical Modeling and Experimental Validation of Cutting Forces Considering Edge Effects and Size Effects With Round Chamfered Ceramic Tools

The cutting force is one of the key factors for planning and optimizing the machining operation in material removal processes. An analytical cutting force prediction model that takes into consideration both edge effects and size effects based on the oblique cutting theory is developed and analyzed in this study. A detailed analysis of the cutting geometry is presented based on the coordinate system transformation and uncut chip thickness (UCT), which is evaluated on the rake plane instead of the reference plane. Then, the developed Johnson–Cook constitutive model of the workpiece that takes into consideration the size effects is then applied to the prediction of edge forces coefficients and cutting forces coefficients. The edge forces are predicted using the edge coefficients prediction model with the regularity found in the orthogonal simulations, which reflect the influences of chamfered length and chamfered angle. The developed model is validated using the turning operations of super alloys with round chamfered inserts. Finally, the effects of the cutter edge, cutting parameters, and UCT on the cutting forces are investigated using the developed model. The reasonableness and effectiveness of the proposed model is demonstrated through the comparison of the measured and predicted cutting forces for various chamfer characteristics.