Developing a mathematical model for the cutting forces prediction depending on the cutting parameters variation in turning

In this present study includes the experimentally determination of the cutting forces which occur during metal cutting, and developing a mathematical model for the cutting forces prediction depending on the cutting parameters variation. For this purpose, various cutting experiments were carried out under dry conditions using cutting tools have 0,4-0,8-1,2 mm nose radiuses, and PM, QM, PR chip breaker forms. A total of 96 machining tests were performed on AISI 1050 steel using three cutting speeds (300, 350, 400 m/min), two feed rates (0,2-0,4 mm/rev), and two depth of cuts (1-2 mm). The cutting forces occurred during metal cutting were measured simultaneously by Kistler 9257B dynamometer. The effects of the cutting parameters and the cutting tool geometry on the cutting forces were investigated. Unlike the literature, two practicable mathematical models for every one of the cutting force components as the primary cutting force, the feed force and the passive force was developed using the cutting force data measured by cutting tests. While cutting speed, feed rate, depth of cut and rake angle of the chip breaker form are used in the first developed model, in addition to the first model, the nose radius is used in the second model for the prediction of the cutting forces. A good agreement between the results of the developed models for the cutting force components and the results of experimentally obtained the cutting force data was seen. Especially, the second model added the nose radius was the more convergent and feasible