APPLICATION OF FRACTIONAL FACTORIAL DESIGN AND DIMENSIONAL ANALYSIS FOR ANALYSIS OF MAIN CUTTING FORCE IN TURNING

Abstract

Cutting forces are very important aspect of machining processes because they directly affect heat generation and cutting power, tool life and energy consumption. Cutting forces can also be used as an auxiliary criterion for the evaluation of material machinability. This paper presents the application of dimensional analysis (DA) model for prediction of the main cutting force in dry longitudinal single-pass turning of not heat-treated non-alloyed and low-alloyed steels with carbon content higher than 0.55%. A fractional factorial design was used to arrange six parameters: depth of cut, feed rate, cutting speed, rake angle, cutting edge angle and tensile strength as workpiece material mechanical property. The machining calculator of the cutting tool manufacturer was used for estimating the main cutting force for five workpiece material groups. The analysis of the results encompassed the evaluation of main and interaction effects of the considered parameters, the development of quasi-linear and DA-based prediction models, and the interpretation of the DA model coefficients. The experimental and validation results indicated that the DA model has good potential for prediction of the main cutting force in turning processes.