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Analytical modeling and prediction of cutting forces in orthogonal turning: a review

  • Critical Review
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The knowledge of cutting forces in various machining processes is of great importance not only for the designer-manufacturer of machine tools, but also for the user, since the cutting force governs cutting heat generation, tool life, and machining accuracy. In this regard, lots of investigations have been conducted on the cutting forces by developing different types of prediction models to make appropriate estimations, which are grouped into the analytical, empirical, and numerical methods. This paper conducts a survey on the development of analytical cutting force models for the orthogonal turning/cutting process. The analytical force models developed from the shear theory are detailed reviewed, and other analytical modeling methods for specially-designed tools, advanced materials, and special kinematics are also presented. The modeling laws and key challenges are also discussed for future researches.

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Availability of data and material

All data, models, and code generated or used during the study appear in the submitted article

Abbreviations

\({\alpha }_{o}\) :

Nominal rake angle

\({\alpha }_{e}\) :

Effective rake angle

\(\beta\) :

Friction angle at tool-chip interface

\(\varphi\) :

Shear angle

\(\theta\) :

Angle between the resultant force and shear plane

A 0 :

Cross-sectional area of the undeformed chip

A s :

Area of the shear plane

A c :

Cross-sectional area of the chip

\(h\) :

Nominal depth of cut

\(w\) :

Width of cut

w chip :

Width of chip

\({r}_{e}\) :

Cutting edge radius

r t :

Tool nose radius

\({t}_{c}\) :

Chip thickness

\({t}_{u}\) :

Uncut chip thickness

\({h}_{\mathrm{min}}\) :

Minimum cutting depth

\({r}_{c}\) :

Cutting ratio

\({F}_{f}\) :

Friction force

\({F}_{n}\) :

Normal force

\({F}_{c}\) :

Main cutting force

\({F}_{t}\) :

Thrust force

\({F}_{x}, {F}_{y}, {F}_{z}\) :

Cutting forces in x, y and z-direction of the machine coordinate system, respectively

\({F}_{R}\) :

Resultant cutting force

\({F}_{s}\) :

Shear force along the shear plane

\({F}_{p}\) :

Ploughing force

σs :

Shear stress along the shear plane

\({\tau }_{s}\) :

Shear flow stress along the shear plane

ρ :

Density

λ k :

Temperature conductivity

σ t :

Ultimate tensile strength

\({v}_{c}\) :

Cutting velocity

\(f\) :

Feed rate

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Funding

The authors received financial support from National Natural Science Foundation of China (no. 51975128, no. 52005110).

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  1. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, China

    Wang Sujuan, Deng Wenping & Sun Zhanwen

  2. Guangdong Provincial Key Laboratory of Micro-Nano Manufacturing Technology and Equipment, School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou, China

    Wang Sujuan & Zhang Tao

  3. State Key Laboratory in Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Kowloon, Hong Kong

    Sandy To

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  1. Wang Sujuan
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  4. Sun Zhanwen
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Wang Sujuan: Final manuscript writing; Zhang Tao: Original draft preparation; Deng Wenping: Manuscript format; Sun Zhanwen: Sections including challenges and opportunities conclusion writing; Sandy To: abstract writing and supervisor

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Sujuan, W., Tao, Z., Wenping, D. et al. Analytical modeling and prediction of cutting forces in orthogonal turning: a review. Int J Adv Manuf Technol 119, 1407–1434 (2022). https://doi.org/10.1007/s00170-021-08114-y

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