Prediction of friction angle and cutting force considering sticking friction in machining process

Sticking friction is a significant factor which influences the tribological behavior at the chip-tool interface and cutting force. This study proposed a simplified cutting force prediction model based on friction angle calculation. Sticking friction has been incorporated to predict the friction behavior. The working rake angle has been determined as a function of tool rake angle, feed rate, and cutting speed. The normal and shear stresses developed on the chip segment have been estimated based on the sticking friction and material yield stress. Based on the stresses developed, the friction angle has been determined. Further the shear angle has been calculated using Lee-Shaffer model. Eventually, the cutting force and thrust force have been determined considering orthogonal machining process. The proposed model was able to predict the cutting force with an average of 4.27% error and improved the prediction accuracy by approximately 7 times as compared to the conventional model.