Predictive Modeling of Cutting Force Based on Local Friction Coefficient Model

Considering the friction of dull radius and the flank face at cutting edge, a new cutting force prediction model was established based on local friction coefficient model of steady-state orthogonal cutting. Mathematical stress analysis models were set up respectively for friction zones on rake surface, flank surface and cutting edge surface. A series of orthogonal cutting experiments were conducted with high-speed steel tool (W6Mo5Cr4V2Al) and 20Cr2Ni4 alloy steel. Primary cutting force and radial thrust force were detected by three-dimensional dynamometer. In the end, the effect of cutting speed, cutting depth and tool rake angle on the magnitude of cutting forces were analyzed. Results show that, the predicted cutting forces calculated from the prediction model are consistent with the test data. It turned out that cutting force has a slightly tendency to decrease with the increase of cutting speed and tool rake angle, significantly increased with the increase of cutting depth.