Development of a general tool model for turning operations based on a variable flow stress theory

Abstract A model for chip flow direction is presented which combines the cutting action occurring at the primary cutting edge, nose radius edge and end cutting edge of general turning tools with inclination angles. The model determines an equivalent cutting edge which caters for the variations in the tool geometry and cutting conditions and the parameters of the equivalent cutting edge are used in a machining theory to predict the cutting forces. The results obtained theoretically and experimentally are in good agreement.