Analysis of an equivalent tool face for the cutting speed range prediction of complex grooved tools

Manufacturers need to obtain optimal operating parameters with a minimum set of experiments as well as minimizing the simulations in order to reduce machining set up costs. The cutting speed, Vc, is one of the most important cutting parameter to evaluate; it clearly most influences, on one hand, tool life, tool stability, and cutting process quality, and on the other hand controls production flow. In addition, in todayʹs applications, complex groove geometries have made more difficult the assessment of cutting models for the prediction of tool-material–work-material combination behaviour. In this paper, an original approach based on the experimental estimation of the friction coefficient and enabling to simplify the complex groove geometry in a flat rake face is presented. A model for cutting force prediction is also proposed. Four different complex grooved inserts and three different cutting tool material grades for each insert are studied for the modelling approach. Orthogonal cutting simulations using the Thirdwave Systems’ AdvantEdge code package are compared with experimental measurement. Results show good agreement and that this approach may reduce both number of experiments and simulation times to determine the cutting speed range. Finally, the paper ends with discussions and concluding remarks.