Quantitative understanding of cutting forces under hard turning conditions is important for thermal modeling, tool life estimation, chatter prediction, and tool condition monitoring purposes. Although significant research has been documented on the modeling of forces in the turning operation in general, turning of hardened materials involves several distinctive process conditions, including negative tool rake angle, large tool nose radius, and rapid tool wear. These process conditions warrant specific treatment in the analysis of cutting forces. This paper first addresses these issues by formulating an oblique chip formation force model through the extension of a two-dimensional (2D) mechanistic force model while considering the effect of tool geometry complexities. The coefficients of the mechanistic force model are estimated by applying a genetic algorithm in overcoming the lack of explicit normal equations. Then the forces occurring due to flank wear are modeled by extending a 2D worn tool force modeling approach into a three-dimensional analysis to accommodate the effect of low feed rate, small depth of cut, and relatively large tool nose radius in hard turning. The total cutting forces are the linear summation of forces due to chip formation and forces due to flank wear. The model-predicted forces match well with experimental results in the turning of hardened 52100 bearing steel under practical cutting conditions (low feed rate, small depth of cut, and gentle cutting speed) using cubic boron nitride (CBN) tools under the progressive tool flank wear conditions.
Skip Nav Destination
e-mail: steven.liang@me.gatech.edu
Article navigation
Technical Papers
Modeling of Cutting Forces Under Hard Turning Conditions Considering Tool Wear Effect
Yong Huang, Assistant Professor,,
Yong Huang, Assistant Professor,
Department of Mechanical Engineering, Clemson University, Clemson, SC 29634-0921
Search for other works by this author on:
Steven Y. Liang, Professor,
e-mail: steven.liang@me.gatech.edu
Steven Y. Liang, Professor,
George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Search for other works by this author on:
Yong Huang, Assistant Professor,
Department of Mechanical Engineering, Clemson University, Clemson, SC 29634-0921
Steven Y. Liang, Professor,
George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
e-mail: steven.liang@me.gatech.edu
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received October 23, 2001; revised July 5, 2002. Associate Editor: M. Davies.
J. Manuf. Sci. Eng. May 2005, 127(2): 262-270 (9 pages)
Published Online: April 25, 2005
Article history
Received:
October 23, 2001
Revised:
July 5, 2002
Online:
April 25, 2005
Citation
Huang, Y., and Liang, S. Y. (April 25, 2005). "Modeling of Cutting Forces Under Hard Turning Conditions Considering Tool Wear Effect ." ASME. J. Manuf. Sci. Eng. May 2005; 127(2): 262–270. https://doi.org/10.1115/1.1852571
Download citation file:
Get Email Alerts
Related Articles
Chatter Stability of General Turning Operations With Process Damping
J. Manuf. Sci. Eng (August,2009)
On Predicting Softening Effects in Hard Turned Surfaces—Part II: Finite Element Modeling and Verification
J. Manuf. Sci. Eng (August,2005)
Analytical Modeling of Chatter Stability in Turning and Boring Operations—Part II: Experimental Verification
J. Manuf. Sci. Eng (August,2007)
On a Novel Tool Life Relation for Precision Cutting Tools
J. Manuf. Sci. Eng (May,2005)
Related Proceedings Papers
Related Chapters
Effectiveness of Minimum Quantity Lubrication (MQL) for Different Work Materials When Turning by Uncoated Carbide (SNMM and SNMG) Inserts
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)
On-Line Cutting Tool Condition Monitoring in Turning Processes Using Artificial Intelligence and Vibration Signals
International Conference on Advanced Computer Theory and Engineering, 4th (ICACTE 2011)
Cutting Performance and Wear Mechanism of Cutting Tool in Milling of High Strength Steel 34CrNiMo6
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)