Analytical prediction of cutting forces in cylindrical turning of 304 stainless steel using unequal division shear zone theory.

In order to establish a more accurate prediction model of turning forces, this paper proposed an analytical model for cylindrical turning with the consideration of the effect of the main cutting edge angle and the nose radius. Meanwhile, the unequal division shear zone theory in orthogonal free cutting is extended and applied to the oblique non-free cutting in the interaction between the chip units. To take into account the real tool nose geometry, the tool nose involved in the cutting is discretized into a series of cutting edge units. The geometrical parameters associated with the cutting edge units are analysed by using the coordinate transformation approach. Then, the improved oblique cutting model is applied to each cutting edge unit to acquire the component forces along the tool rake face. Finally, the resultant cutting forces in the turning process are calculated by the numerical integration method. To verify the effectiveness of the proposed model, the turning force experiment of 304 stainless steel was carried out by changing the cutting conditions, the main cutting edge angle, and the nose radius. Through the comparative analysis between the measured results and the calculation values of the proposed model, it was found that the analytical prediction of cutting force is in good agreement with the experiment. [ABSTRACT FROM AUTHOR]