Predicting cutting force with unequal division parallel-sided shear zone model for orthogonal cutting

摘要

Predicting cutting force is always the research hotspot due to its significant effect on machining process. In this work, an analytical model of cutting force based on unequal division parallel-sided shear zone has been developed for orthogonal cutting. An unequal division parallel-sided shear model together with a prediction model of shear angle are integrated into the shear cutting force model in the primary shear zone. The classical Waldrof's slip-line model is employed to describe the plow effect induced by edge radius of cutter and then the plow cutting force is calculated. The modeling algorithm of cutting force is subsequently proposed by integrating the shear cutting force with the plow cutting force. Cylindrical turning of Inconel 718 alloy is taken as a case to verify the proposed prediction model of cutting force. The measured results show that the predicted cutting force agrees well with the measured value. The average prediction errors of the main cutting force and the feed force are 8.39% and 12.03%, respectively. Compared with the classical shear models, it is found that the developed cutting force model shows higher accuracy on predicting cutting force. Additionally, the proposed model is then further verified by predicting cutting force with five different J-C constitutive models.