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International Journal of Machine Tools & Manufacture 46 (2006) 13881394 www.elsevier.com/locate/ijmactool

A model for cutting forces generated during machining with self-propelled rotary tools
L. Li, H.A. Kishawy
Department of Mechanical Engineering, University of New Brunswick, Post Ofce Box 4400, Frederiction, NB, Canada E3B 5A3 Received 17 September 2005; accepted 4 October 2005 Available online 8 November 2005

Abstract In this paper, a force model for self-propelled rotary tool is presented. Conventional oblique cutting force predictions were reviewed and extended to predict the cutting forces generated during machining with the self-propelled rotary tools. The model presented is based on Oxleys analysis and was veried by cutting tests using a typical self-propelled tool. Good agreement was obtained between the predicted and the experimentally measured forces under a wide range of cutting conditions. The effect of different cutting conditions on the friction coefcient along the chip/tool interface and tool rake face normal force were also presented and discussed. r 2005 Elsevier Ltd. All rights reserved.
Keywords: Cutting force; Self-propelled rotary tool; Chip ow angle; Friction coefcient

1. Introduction Machining with rotary tools has received a considerable attention from researchers during the past decades [17]. More recently, the superior wear resistance has encouraged several researchers to utilize these tools to machine difcult to cut materials [811]. In cutting with a rotary tool, a circular insert is used and allowed to freely rotate about its axis. As a result of the insert rotation the wear is distributed over the entire circumference of the circular insert, thus providing a longer tool life. In addition, the insert rotation provides a self-cooling feature that reduces thermally induced wear. For example, during hard turning with self-propelled tool no crater wear was reported while under the same cutting condition, crater and ank wear were observed when conventional cutting tools were used [11]. Based on studying the heat transfer during cutting with rotary tools it was shown that a minimum tool temperature can be achieved at an optimum rotational speed of the insert [12].

Corresponding author. Tel.: +1 506 458 7767; fax: +1 506 453 5025.

E-mail address: kishawy@unb.ca (H.A. Kishawy). 0890-6955/$ - see front matter r 2005 Elsevier Ltd. All rights reserved. doi:10.1016/j.ijmachtools.2005.10.003

The rotation of the circular insert makes the kinematics of the process much more complicated as compared to conventional cutting. It has passed a long way since the discovery of the advantage of cutting using rotary tools and most of the research is related to the applications of rotary tool and how it will benet the machining process. Several researchers have explored the theoretical analysis of rotary cutting [12,46,12]. Shaw et al. [1] gave the primary study on rotary tool machining and presented an analysis to quantify the velocity relations in rotary cutting. Armarego and Karri [2,46] presented a more comprehensive analysis for cutting with rotary tools and predicted the forces generated during machining with rotary tools. However, their analysis did not consider the radius of the cutting insert. In addition, their experimental validation was achieved by using a tool with straight cutting edge that was given an additional motion along the edge direction to simulate rotary tools. According to the open literature all the available analysis for cutting with rotary tool are based on using straight cutting edge that is allowed to slide parallel to the edge direction to simulate the rotary motion except the recently presented model for prediction of chip ow angle [13]. Modeling of the process based on a typical rotary tool

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Nomenclature Bw Bwr Bx f fy FC FR FT i ir iw absolute undeformed chip width relative undeformed chip width insert effective cutting edge width feed equivalent feed on the tool rake face cutting force force component normal to FC and FT in oblique cutting feed force inclination angle rotary tool insert effective inclination angle the angle between workpiece absolute velocity direction and the intersection direction of cutting edge normal plane Pn and cutting edge plane Ps the angle between workpiece relative velocity direction and the intersection direction of cutting edge normal plane Pn and cutting edge plane Ps

M Nr r R

iwr

transformation matrix insert revolution insert radius resultant force at shear zone or toolchip interface Rm the resultant force in machine coordinate system RX, RY, RZ coordinate system transformation matrices t1 undeformed chip thickness Vw workpiece absolute velocity Vwr workpiece relative velocity w orthogonal cutting chip width, tube shape workpiece wall thickness a tool rake angle an normal rake angle, rotary tool insert effective rake angle Zc chip ow angle, relative chip ow angle in rotary cutting process w the difference of iw and iwr O resultant chip ow direction

geometry to predict the forces generated will enable a more realistic analysis that will provide information about the effect of circular edge radius and facilitate an effective selection of process parameters. In this paper an attempt has been made to utilize Oxleys analysis for oblique machining and extend it to predict the equivalent oblique cutting forces generated when using selfpropelled rotary tools. A previously presented model by the authors [13] for predicting the chip ow angle in rotary tools is also utilized here to predict the cutting forces. 2. Method for force prediction in conventional oblique cutting In oblique machining, the chip ow direction is no longer normal to the cutting edge. This complex condition impedes the analysis in oblique cutting. However, attempts have been made to approximate the analysis and predict the cutting forces [14]. According to the machine coordinate system, conventional oblique cutting forces are shown in Fig. 1. Armarego and Brown [15] pointed out their experimental observation for the oblique cutting in terms of cutting forces and chip ow angle. For a given normal rake angle an and other cutting conditions, the cutting force FC and feed force FT are nearly independent of inclination angle i. The chip ow angle was also elaborated by following the Stablers chip ow rule [16]. Lin et al. [17] extended this method and detailed that the oblique cutting force FC and feed force FT could be obtained from the orthogonal cutting with zero inclination angle and using the normal rake angle (an) as the rake angle (a). The third force component FR (i.e., normal to FC and FT) was calculated by considering the inclination angle i. The

Cutting velocity V FT

t1 Fc

O FR i n c Q B X Y Z

Fig. 1. Conventional oblique cutting forces [14].

resultant force vector R can be expressed as R F R ; F T ; F C T . (1)

The resultant force R was considered to be acting in the plane normal to the tool rake face and having the resultant friction force direction. Since the normal plane to the rake face contains the resultant force R and the resultant friction force F (F acts along the chip ow direction), there should be no force component normal to this plane. This is carried out by rotating the machine coordinate system around the Y-axis to make X-axis in the direction of the cutting edge,

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and around the X-axis to place the rake face in the XY plane. Finally, rotate the system around Z-axis to align the Y-axis along the chip ow direction. The coordinate transformation system from the machine coordinate to the nal one can be expressed as M RZ Zc RX an RY i (2)

where RX, RY, and RZ are the coordinate system transformation functions for the given rotation angle around X-, Y-, and Z-axes, respectively. The resultant force R in the nally created coordinate system is Rnal, given by Rfinal RZ Zc RX an RY iR. (3)

The expression for FR can be obtained by setting the X direction component to zero in Rnal as FR F C sin i cos i sin an tan Zc F T cos an tan Zc . sin i sin an tan Zc cos i (4)

The cutting force FC and feed force FT can be obtained using Oxleys theory [14,18,19]. 3. Cutting force prediction in self-propelled rotary tool cutting processes The rotation of the circular insert adds another complication to the relations among the chip, tool and

velocity relations and relative chip ow direction have been obtained during the cutting process with self-propelled rotary tools. Considering that the insert radius is much larger than the tube thickness, the equivalent cutting edge is considered as a straight line. In this analysis, the previously presented force model for orthogonal machining [14,18,19] is extended to conventional oblique cutting, and then used in the equivalent conventional oblique cutting of the rotary cutting. The analysis accounts for the nose radius and the effect of chip ow angle to predict the forces generated during cutting with self-propelled rotary tools. In this equivalent conventional oblique cutting, the cutting velocity is the relative undeformed chip velocity, Vwr, the undeformed chip thickness is the relative undeformed chip thickness, Bwr, the rake angle is the same as the insert working rake angle, an, and cutting edge inclination angle is iwr. Fig. 2 illustrates the relation between different coordinate systems to analyze the kinematics of cutting with rotary tools. The cutting force FC and feed force FT are calculated using Oxleys orthogonal cutting force prediction method with the workpiece relative velocity, Vwr, undeformed chip width, Bwr, and feed f. Eq. (4) is employed to calculate FR using the relative inclination angle iwr, effective normal rake angle an, and the relative chip ow angle Zc. The chip ow angle Zc is calculated by considering the nose radius of the insert such that:

0R 1 R p=2 R y3 R y4 y2 y1 sin O1 rt1 y dy y2 sin O2 rt2 y dy p=2 sin O3 rt3 y dy y3 sin O4 rt4 y dy A Zc atan@R y . R p=2 R y3 Ry 2 cos O1 rt1 y dy y2 cos O2 rt2 y dy p=2 cos O3 rt3 y dy y34 cos O4 rt4 y dy y1 workpiece. The presented model accounts for the insert rotation as well as insert radius through its effect on the chip ow direction. However, it should be mentioned here that, the presented force model is limited for the case of tube-end cutting using self-propelled rotary tools. To simplify the analysis, the following assumptions are made: (1) Insert radius is much larger than the tube thickness. (2) Continuous chip is formed with uniform velocity at all the points on the chip. (3) The resultant force at the toolchip interface balances resultant force at the primary deformation zone. (4) Collinearity exists between the friction force direction and the direction of relative chip ow on the tool rake face. (5) There is no workpiece material side ow during the chip formation process. The predictions of cutting forces have been explored for orthogonal cutting [14,18,19], conventional oblique cutting [1517], and nose radius tip cutting [20,21]. The current rotary tool force model applies Armarego et al. [46] transformation from rotary cutting to conventional oblique. In the early stage of this investigation [13], the

(5)

The equivalent oblique cutting force prediction is under the original coordinate system in Fig. 2(b). A resultant force R is used to express the three predicted components in relative velocity coordinate system as Eq. (1). In order to compare the predicted and the experimental results, the resultant force R is resolved in the machine coordinate system. The resultant force in machine coordinate system Rm is expressed as Rm Ry wR, where w is w iw iwr . (7) (6)

So the three elements in Rm are the values corresponding to the output measured using the dynamometer during cutting test. The ow chart in Fig. 3 summarizes the selfpropelled rotary tool cutting force prediction method. 4. Experimental work A self-propelled rotary tool was employed in the current investigation to carry out the machining tests. A typical rotary tool consists of a tool holder and a circular insert xed to the tool holders cartridge. Uncoated carbide

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intersection line of Ps and Pn Z Cross slide direction Machine spindle direction Y

PS Z iW iwr

intersection line of Ps and Pn

PS Z iW

iwr Y iW X iwr Y

iW

iwr

X X (a) (b) cutting edge (c)

cutting edge

Fig. 2. The coordinate system transformations in the cutting force prediction process. (a) Machine coordinate system; (b) original coordinate system; and (c) machine coordinate system for cutting forces.

Start Input: Vw , Bw , ir , n , r, Nr

Vwr , Bwr Input: Material properties & Initial conditions Functions for Orthogonal cutting force prediction Input: f

iwr

Equivalent parameters on the tool rake face: Bx , fy Relative chip flow angle : c [13]

Orthogonal cutting forces: FC , FT

Oblique cutting force in original coordinate system: R = [-FR , FT, -FC]T

Resultant force in machine coordinate system: Rm = Ry (-) R Resultant

End
Fig. 3. The ow chart for cutting force prediction in rotary cutting.

Fig. 4. Cutting tool installation on the tool post.

inserts with 27 mm diameter, 01 rake angle and 01 ank angle are used. When the insert, cartridge, and tool holder are assembled, the cutting edge has 171 inclination angle and 51 rake angle. The tool is fed in the machine spindle direction, as shown in Fig. 4. The material used in this investigation was carbon steel SAE1045 in form of tubes of 48 mm diameter and 2 mm wall thickness. The material composition is shown in Table 1. The cutting forces were recorded using a 3-component force dynamometer (Kistler 9251A) and three charge

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1392 Table 1 Carbon (C) 0.430.50% Manganese (Mn) 0.600.90% Phosphorus (P) 0.04% Sulfur (S) L. Li, H.A. Kishawy / International Journal of Machine Tools & Manufacture 46 (2006) 13881394

1000 800 force (N) 600 400 200 Workpiece Rotary tool Toolpost with dynamometer (a) 1000 800 force (N) 600 400 200 0 0.09 Data acquisition board (b) 1000 800 force (N) 600 400 200 0 0.09 (c) 0.11 0.13 0.15 0.17 feed (mm/rev) 0.19 0.11 0.13 0.15 0.17 feed (mm/rev) 0.19 0 0.09 0.11 0.13 0.15 0.17 feed (mm/rev) 0.19 Radial force: prediction experiment Axial force: prediction experiment Cutting force: prediction experiment 0.21

0.05%

Radial force: prediction experiment Axial force: prediction experiment Cutting force: prediction experiment 0.21

Feed direction

Radial force: prediction experiment Axial force: prediction experiment Cutting force: prediction experiment 0.21

Amplifier Computer

Fig. 6. The predicted and measured effect of feed on the cutting force at different speeds: (a) cutting speed 120 m/min, (b) cutting speed 170 m/min, and (c) cutting speed 230 m/min. Fig. 5. The schematic diagram of the dynamometer working system.

ampliers (PCB Charge Amplier MOD 462A). To verify the model prediction, three cutting speeds were employed: 120, 170, and 230 m/min. Four feeds were used including 0.1, 0.125, 0.15, and 0.2 mm/rev. The cutting was carried out under dry conditions (Fig. 5).

5. Results and discussion Fig. 6 shows a comparison between the predicted and measured cutting forces during machining with selfpropelled rotary tool. The predicted forces are comparable to the measured ones. Also, the predicted effect of the feed and cutting speed is in agreement with the measured one. From the above comparison, the predictions have an error percentages about 15%. It should be mentioned here that the cutting tests have been repeated in all cases with an error percentage less than 3%, where much lower prediction error percentages were recorded in the axial and cutting forces.

The reason is due to the following three factors. The rst is that the prediction of the radial force uses the insert inclination angle as the cutting edge resultant inclination angle, but the actual situation is that the cutting edge is an arc segment. There is a technical difculty in measuring the relative chip ow angle, and no quantitative analysis applies here. The second factor may be the tool adjustment process. If the rotary tool insert cutting edge tip (rst touching point) is not at the tube thickness center position, the actual chip ow and the actual relative chip ow direction will be changed and nally affect the radial force. The third factor is that the magnitude of the radial force is small, so the small change in the value will result in a higher value of error percentage. Also the use of mean velocity will affect the chip ow direction. No side ow was assumed. In addition, tests showed burr formation under various conditions, and in some cases serrated-side chips were formed. This will affect the absolute chip velocity calculation and the prediction of the absolute chip ow angle. In this experiment, all the above-mentioned error

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sources were reduced as much as possible by repeating the cutting test several times. In all cases the measured forces were almost the same with a difference of few Newtons when the magnitude was in the order of hundreds. Also, the tool position was adjusted to the tube-end position and the machine dynamometer was recalibrated for the experiment. The predicted friction coefcients and normal forces are shown in Figs. 7 and 8. The friction coefcients decrease with the increase of the feed. This trend was observed at different velocities. It was also found that the friction coefcient decreases with the increase of cutting velocity. The variation trend of the friction coefcients in this model is the same as that of the data obtained by Merchant (1945), and Lapsley et al. (1950) [22]. There is also a technical challenge in measuring the rotary cutting toolchip interface friction coefcient. There is very slight change in the normal force to the tool rake face with changing cutting velocities. The tool rake face normal force in Fig. 8 is not the result of force transformation of the output from the dynamometer to the tool rake face, because the relative motion of workpiece and insert, and

the relative motion of chip and insert are different from which discussed in the conventional cutting process. In the current model, material properties are used directly according to Oxleys theory with no need for calibration, and relative chip ow angle was calculated based on the tool geometry and cutting conditions, where previous rotary tool force model [5] was based on nding the relative chip ow angle by iteration and using data bank of orthogonal cutting tests for different materials and various cutting conditions. In addition, an actual rotating tool was used in the cutting tests. However, there are certain limitations in the models ability to predict the cutting forces. The rst is that the model has been developed by assuming a at tool rake face plane. For the rotary tool insert with a chip breaker, new mathematical methods and assumptions are needed in future study. The second limitation is that the force prediction in this model is based on Oxleys theory which considers the plane-strain condition, and so the undeformed chip thickness should not be larger than 1/10 of the tube thickness. 6. Conclusion

0.6 0.5 friction coefficient 0.4 0.3 0.2 0.1 0 0.09 V=120 m/min V=170 m/min V=230 m/min

0.11

0.13

0.15 0.17 feed (mm/rev)

0.19

0.21

A force model for the self-propelled rotary tool is presented and validation of the model was carried out by conducting experiments under different cutting conditions. The predicted cutting forces were within the limits of divergence. The model was utilized to predict the friction coefcient at toolchip interface for a typical self-propelled rotary tool. It was shown that increases in feed and cutting velocity results in lower friction coefcient. The normal force on the tool rake face was found to be sensitive to the changes in feed. There is only a slight difference in the value of the normal force for a given feed at different cutting velocities. Acknowledgment

Fig. 7. Comparison of friction coefcient vs. feed under various cutting velocities.

The authors acknowledge the support of Natural Sciences and Engineering Research Council of Canada, NSERC. References

1000 800 600 400 200 0 0.09 V=120 m/min V=170 m/min V=230 m/min
[1] M.C. Shaw, P.A. Smith, N.H. Cook, The rotary cutting tool, Transactions of the ASME (1952) 10651076. [2] V. Karri, Fundamental studies of rotary tool cutting processes, Ph.D. thesis, University of Melbourne, 1991. [3] E.J.A. Armarego, V. Karri, A.J.R. Smith, Computer-aided predictive models for fundamental rotary tool cutting processes, Annals of the CIRP 42/1 (1993) 4954. [4] E.J.A. Armarego, V. Karri, A.J.R. Smith, Fundamental studies of driven and self-propelled rotary tool cutting processII. Experimental investigation, International Journal of Machine Tools & Manufacture 34 (6) (1994) 803815. [5] E.J.A. Armarego, R.K. Katta, Predictive cutting model for forces and power in self-propelled rotary tool turning operations, Annals of the CIRP 46/1 (1997) 1924.

normal force (N)

0.11

0.13

0.15 0.17 feed (mm/rev)

0.19

0.21

Fig. 8. Comparison of normal force vs. feed under various cutting velocities.

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