An analytical evaluation of the cutting forces in orthogonal cutting using a dynamic model of the shear zone with parallel boundaries

A shear zone model with parallel boundaries is used to evaluate the dynamic cutting forces in orthogonal cutting. The cutting system was modeled using a single degree-of-freedom dynamic system where the variations of the cutting forces are represented by their total differentials. The influence of temperature on the flow shear stress of workpiece material is accounted for. The experimental verification of the proposed model was performed using a two-component piezoelectric dynamometer and adopting the rotating cutting tool-stationary workpiece procedure. The dynamometer was calibrated for static and dynamic outputs and techniques were employed for increasing the measurement accuracy and reducing cross-influence by obtaining the elements of transfer and coherent functions. Experiments were carried out to measure the dynamic fluctuations of the force components. The experimental results show good agreement with the theoretical evaluations of the cutting force components. (C) 1998 Elsevier Science S.A. All rights reserved.