Force decomposition model for tool-wear in turning with grooved cutting tools

K. C. Ee, A. K. Balaji, P. X. Li, I. S. Jawahir

Research output: Contribution to journalArticlepeer-review

18 Scopus citations


The lack of a satisfactory methodology to predict the tool-wear progression/tool-life in a machining operation with a grooved tool necessitates development of quantitative predictive models for tool-wear. This paper presents a new methodology for decomposing and distributing the resultant force generated in machining with a grooved tool within the three major tool-wear regions: edge region, secondary-face region, and groove backwall region. By measuring the edge force from the experiments, the forces acting on the other two major wear regions can be found from the kinematics of the 3-D chip-flow and the geometry of the tool insert. The Coulomb coefficient of friction is assumed only at the groove backwall region. The effect of chip side-flow is considered by measuring the chip side-flow angle from experiments using high speed filming techniques. With the new methodology, the decomposed forces acting on the wear regions can be related to the dominant wear modes of a grooved tool. The new methodology implicitly includes the influencing parameters on tool-wear, including cutting conditions, tool geometry and chip-groove geometry, since changes in these parameters are reflected in the cutting forces. This force decomposition method offers a new approach for predicting the cutting tool-wear analytically using the measured cutting forces.

Original languageEnglish
Pages (from-to)985-994
Number of pages10
Issue number10-11
StatePublished - Nov 2001

Bibliographical note

Funding Information:
The authors of this paper gratefully acknowledge the financial support provided by the National Science Foundation (DMII 9624640) and the administrative support by the Center for Robotics and Manufacturing Systems at the University of Kentucky.


  • Force decomposition
  • Grooved tools
  • Tool-wear

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry


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