Cutting Force Simulation of Machining with Nose Radius Tools

The mechanics of cutting with nose radius tools is discussed in the current paper. B-spline parametric curves are used to model the cutting edge and un-deformed chip area. The nose area is divided into elements which are normal to the elemental cutting edge. For the rest of the chip area the approach angle remains constant; thus, there is no need to subdivide this region and is considered as a single element. The elemental area and cutting edge contact length are found with an analytical algorithm for B-spline curves intersection. Cutting force is correlated to the chip area and cutting edge with cutting coefficients which are extracted from an orthogonal database. Accordingly, the elemental cutting force components can be computed. Summing up all the forces along the cutting edge provides the resultant cutting force. In addition, experimental cutting tests have been conducted to measure the cutting components along x-, y- and z-axis. The predicted results are in good agreement with experimental observations for a wide range of cutting conditions.