An Empirical Tool Force Model for Precision Machining

[+] Author and Article Information
C. Arcona

IBM Corp., San Jose, CA 95193

Th. A. Dow

Precision Engineering Center, North Carolina State University, Raleigh, NC 27695-7918

J. Manuf. Sci. Eng 120(4), 700-707 (Nov 01, 1998) (8 pages) doi:10.1115/1.2830209 History: Received September 01, 1996; Revised August 01, 1997; Online January 23, 2008


The accuracy of precision machining operations could be improved through tool force feedback. Tool force is ideally suited for use in a control algorithm because it contains information on the instantaneous depth of cut, feed rate and condition of the tool. A tool force model that could form the basis of this new control technique has been developed. By measuring the shear angle from micrographs of chip cross sections, equations for the forces due to chip formation and the friction between the chip and the tool have been written. Furthermore, the effects of elastic deformation of the workpiece (spring back) on chip formation and the measured forces, which can be significant in precision machining, have been included in the model. Machining experiments were conducted with a 0 deg rake diamond tool and four metals that are commonly diamond turned. For machining with newly lapped as well as worn tools, the calculated forces were in excellent agreement with the measured values for the array of workpiece materials.

Copyright © 1998 by The American Society of Mechanical Engineers
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