MODELLING OF PROCESS FORCES FOR COMPLEX MULTIAXIAL TURNING PROCESSES

Abstract

Increasing demands regarding productivity and component quality are a major challenge in turning. To meet these demands, complex multiaxial turning processes like enhanced variants of the trochoidal turn-ing processes are increasingly used. For these processes, the tool path is optimized to achieve advanta-geous cutting conditions and thus higher productivity. However, the process forces and their relations to the process parameters for these processes are currently unknown, which complicates the process de-sign and calculation of required clamping forces. This paper presents a simulation based approach to estimate the process forces of complex multiaxial turning processes. Therefore, a dexel based material removal simulation is used to calculate the chip parameters, e.g. undeformed chip thickness, and the chip cross-sectional area. On this basis, the process forces are modelled as a function of the undeformed chip thickness and undeformed chip width. By this, the force model is parameterized and the calculated process forces are validated by comparison with process force measurements.