Dual-mechanism approach to the prediction of machining forces: Part 2 - model implementation and interpretation

The Dual-Mechanism Machining Force Model (DMMFM) developed in Part 1 of this paper is implemented here. The calibration constraints presented in Part 1 are formulated through an interpretation of machining force trends. This interpretation is based on a qualitative analysis of thermal energy generation and temperature, shear-strain level and shear-strain rate through there relations to the process inputs of chip thickness, cutting speed and rake angle. It is demonstrated how the calibration algorithm is applied given a concise set of experimental orthogonal machining force data. Calibration of a traditional lumped specific cutting and thrust energy model is also presented for comparison purposes. The calibration results are used to study the total machining force predictive capabilities of the two force-modeling approaches. It is shown that the Dual-Mechanism Approach contributes greatly to our ability to both physically explain the trends in the machining force data and to understand their implications. This is achieved through an interpretation of the individual rake and clearance face forces that are predicted using the DMMFM. The interpretation is based on the relations of these rake and clearance face forces to the process inputs through the effects of thermal energy generation and temperature, shear-strain level and shear-strain rate on the DMMFM coefficients.