CAD Based Geometric and Force Modeling of Single Point Form-cutting Tools

AbstractThe paper models Single Point Cutting Tools (SPCTs) with free- form rake and flank surfaces for geometry and cutting forces using CAD. The geometric profile of the rake and flank surfaces has been modeled using NURBS where the control points can be arbitrarily chosen and interactively modified to obtain the desired cutting angles along the cutting edge. Such a model can be employed to design form- cutting tools with optimum profile. The geometric model is used to calculate the rake and flank angles in the prevalent nomenclatures such as ASA, ORS and NRS by obtaining projections to the normal along the cutting edge on the chosen planes. The angles are then used to predict the cutting and thrust forces using a mechanistic equation for HSS tool and MS work- material combination. To validate the results, an HSS tool is ground arbitrarily and the points on the cutting edge and rake face are captured. The control points are derived and the model is fitted to generate the geometry of the tool. Experiment...

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