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Forces induced upon the dry orthogonal cutting of 2024 Aluminum alloy employing controlled contact length tools are predicted via two published models developed by Abdel Moneim. The experimental data, at a cutting speed of 120 m/min, are checked against the theoretical models. Theoretical values for both cutting and thrust forces relevant to tool nose edge are assessed utilizing Abdel Moneim finish machining model. The second theoretical model, offers an approximate upper bound solution for predicting the forces which act upon inclined straight tool rake surfaces utilizing a simplified slip-line field technique. Such two models, combined together, predicted the values of both cutting and thrust forces induced during machining with controlled contact length tools. Experimental force data are recorded by the second author for orthogonal dry machining of solution treated and aged 2024 aluminum alloy at a relatively high speed (120 m/min) selected to avoid complications of active build-up formation. Such data are found to be in fair agreements with theoretical models.

FORCES PREDICTION DURING CUTTING WITH CONTROLLED CONTACT LENGTH TOOLS