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 turning processes are increasingly used. For these processes, the tool path is optimized to achieve advantageous 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 design 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.
Science Journal 