Mechanics and Thermal Models for Machining

Abstract

Predicting forces and temperatures are two of the most common reasons for modeling machining processes. Both of these quantities are needed for practical reasons related to planning a machining operation. Forces exerted by the cutting edge on the workpiece can cause deflections that lead to geometric errors and difficulty meeting tolerance specifications. Reaction forces of the workpiece on the cutting edges can, if large enough, cause catastrophic failure of the cutting edge. The product of the force and velocity vector are used to predict power requirements for sizing a new machine tool or for predicting the production rates possible with an existing machine tool. Temperature predictions are used to estimate how the process of machining or grinding affects a cutting edge’s useful life or how elevated temperatures can change the mechanical properties of the workpiece. Both of these considerations are important for economical operation of the process or the safety and performance of the machined product.