Analysis and modeling of edge forces in orthogonal cutting

In this study, the effect of the hone radius on the cutting forces and flank contact length is investigated experimentally and analytically. An initial analytical approach for the edge cutting forces due to the third deformation zone in orthogonal cutting conditions is proposed. The model predicts the cutting forces by considering the normal pressure and the shear stress distributions on the edge and rake contacts in addition to the sticking and sliding friction zones on the rake face. Orthogonal cutting experiments using uncoated carbide inserts with different edge hone radii are conducted for verification and investigation purposes. The tool-material contact lengths on the flank face are measured in different test conditions, and the effects of the cutting conditions on the contact length are analyzed. The model predictions are compared by experiments and promising results are obtained.