Experimental and analytical investigation of third deformation zone in orthogonal cutting

In this study, an analytical investigation of cutting forces of third deformation zone is presented. An orthogonal cutting model including a thermo-mechanical model with dual zone friction behaviour is proposed in order to determine the effects of hone radius and flank contact on cutting forces. Furthermore different approaches for friction and material behavior are considered for precise modeling. Also full and elastic recovery of the material are considered for contact length calculations for the same reasons. Predictions of the proposed model are compared with the force and thermal measurements and it is shown that the model predictions are reasonably comparable with the experimental data.