Prediction of cutting forces in orthogonal machining.

In this investigation two methods of machining analysis have been used to make predictions of cutting forces from a knowledge of the workpiece material flowstress and the cutting conditions. The first method of the analysis is used withthree different materials namely EN8, Aluminium and 70-30 Brass. In thisanalysis the work material flow stress is obtained from a simple quasi-static compression test where the effects of temperature and strain rate are considered to be negligible. Predicted results for the cutting forces obtained from the first method of analysis were compared with experimental results. The comparisonof predicted results with experimental results shows only limited agreement.In order to improve the agreement between experimental and predicted results the machining model was improved by the inclusion of flow stress properties obtained from high speed compression tests. In addition the effect oftemperature on the flow stress was allowed for by the use of the velocity modified temperature concept. An excellent agreement is shown between predicted cutting forces obtained from the improved model of machining, with the cutting forces obtained by experiment.Conclusions are drawn and suggestions for further work are made.