DEVELOPMENT OF A PARAMETRIC MODEL FOR CALCULATING CUTTING FORCES IN EXTERNAL CYLINDRICAL TURNING OF 20CRMN STEEL (1.7147) USING AN SNMG 15 06 16-PR 4425 INSERT

This article develops and presents a mathematical model for calculating cutting forces during the machining of 20CrMn steel (1.7147) using an SNMG 15 06 16-PR 4425 T-Max® P insert for turning. We conducted experimental research on a specially designed test rig based on the 16D25 lathe. This setup measures spindle speed, feed rate, cutting depth, and the cutting forces generated during the machining process with high precision. We used the LTR-EU-8 workstation for data acquisition and analysis, equipped with galvanic isolated modules and a synchronized data transmission interface to ensure accurate measurements. The system transmitted real-time data to a computer for further processing, which helped verify the theoretical model. The results showed a high correlation with actual measurements: the deviation between calculated and experimental values did not exceed 5.68%, proving the model’s accuracy in predicting cutting forces. This accuracy plays a key role in optimizing machining processes, reducing tool wear, and lowering energy consumption. The study also found that cutting forces provided by major tool manufacturers are often overestimated. In some cases, the discrepancies between calculated and actual forces reached 17.8%, potentially affecting the accuracy of process planning and the choice of optimal cutting parameters. Additionally, the study revealed that the cutting forces typically provided in calculations by leading tool manufacturers are often overestimated. In some cases, discrepancies between calculated and actual force values reached up to 17.8%, which can impact the accuracy of process planning and the selection of optimal cutting parameters.