Modeling of turning process cutting forces for grooved tools

A mechanistic modeling approach to predicting cutting forces for grooved tools in turning has been developed. The model assumes the existence of an equivalent orthogonal cutting operation for any oblique operation. The effects of tool nose radius and chip flow have been incorporated by defining a set of equivalent groove parameters. Two calibration methods have been presented for the model. A variety of commercial grooved inserts were chosen to validate the model. The workpiece material used was AISI 1018 steel. The force predictions from the model were found in good agreement with the measured forces. The effects of cutting conditions and groove parameters on the cutting forces and their implication in designing grooved tools were also determined.