A new approach to predicting machining forces acting on rounded cutting edges

This work presents a method for representing the effect of rounded cutting edges on the process forces by the use of an equivalent rake angle. This allows the calculation of the process forces using mechanistic models based on the specific cutting force obtained for different rake angles and uncut chip thicknesses. For this, orthogonal turning tests were carried out with chamfered cutting inserts and varying feed rates. Similar tests were then conducted with inserts prepared with asymmetrical edge roundings to verify the validity of the method for calculating force components in cutting and thrust directions. By comparing experimental and theoretical results, an average error of 4% was observed for the cutting force, while an average error of 6% was obtained for the thrust force. After analyzing intensity maps of the influence of edge geometry parameters on the process forces, it can be stated that the use of the equivalent rake angle for predicting the forces acting on the cutting inserts with different edge geometries is a viable alternative for process optimization.