Thermo-mechanical modeling of the third deformation zone in machining for prediction of cutting forces

Third deformation zone in machining arises due to contact between the cutting edge and the work material resulting in edge forces. Contribution of edge forces can be significant for cases involving large cutting edge radii or small feed rates. In this study, a thermo-mechanical modelling of the third deformation zone is presented with applications. The model eliminates the need for extensive number of calibration tests for identification of these coefficients. Effects of cutting edge geometry and process conditions on the edge forces are investigated through measurements and predictions. The application of the model to micro milling operations is also demonstrated. (C) 2016 CIRP.