Experimental Investigationson Chip Formation and Plowing Cutting Forces During Hard Turning

Abstract The cutting force analysis has been key parameter to resolve and determine various performance related issues duringhard turning. This work mainly aims to investigate the varying contribution of chip formation and plowing cutting forcesat different cutting conditions duringhard turning.Chip formation and plowing cutting forces were calculated at various cutting conditions using Oxley's predictive machining theory. Sum of chip formation and plowing cutting forces were compared with the experimentalresults obtained during hard turning of AISI 52100 alloy steel(60-62 HRC) using a PVD-applied nanolaminated TiSiN-TiAlN coated carbide tool. It has been observed that chip formation cutting force has a major contribution in the range of 60 to 70% in total cutting force in comparison to plowing force. However, at lower values of depth of cut, plowing forces are predominant as compared to chip formation forces. It has been also observed that chip formation forces are decreasing with increase in cutting speed and increases with increase in feed and depth of cut values.

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