A P20 mold steel shaft with a diameter of D = 57 mm is turned with an S10
grade carbide tool with a side rake angle of αf = −5◦, a back rake angle of
αp = −5◦, and zero approach angle. The nose radius of the insert is r = 0.8
mm. The radial depth of cut, the feed rate, and the cutting speed are a =
1 mm, c = 0.06 mm/rev, and V = 240 m/min, respectively. The orthogonal
dry cutting parameters of P20 mold steel cut by an S10 carbide tool with a
rake angle αr = −5◦ are given as follows:
Shear stress τs = 1400h + 0.327V + 507 [N/mm2],
Friction coefficient βa = 33.69 − 12.16h − 0.0022V [degree],
Chip ratio rc = 2.71h + 0.00045V XXXXXXXXXX,
where the units are in h [mm] and V [m/min].
a. Evaluate the distribution of chip thickness along the curved chip length.
b. Evaluate the cutting coefficients along the curved chip length using the
oblique cutting transformation.
c. Evaluate the distribution of tangential, radial, and feed cutting forces
(Ft,Fr,Ff ) along the curved chip.
d. Find the total cutting forces (Fx,Fy,Fz), torque, and power required to
turn the shaft.