Estimation of Cutting Time in Polygonal Turning through Modeling of Tool Workpiece Interactions in Workpiece Coordinate System

This paper presents detailed investigations into the estimation of cutting time (CT), the percentage of cutting time to total time (%CT/TT), and the reduction in the workpiece cross-section area during the polygonal turning process using complex number representation of the tool tip in an absolute workpiece coordinate system The motive of this study is to bridge the gap between the algorithms for integer and fractional speed ratios reported in the literature and develop a single robust model with structured verification and validation. The model was verified by determining the exact number of sides and the profile geometry produced on the workpiece and comparing the model results with the existing literature. Cutting time was validated experimentally, using a high-speed camera in two scenarios: machining a tri-lobed geometry and a square geometry. The model successfully estimated geometric profiles, and for the specified machining parameters, the estimated number of sides aligned with the reported literature. The model underestimated the experimental value of cutting by 12.35% for a trilobed geometry and overestimated the experimental value by 5.66% for a square geometry.