The unified-generalized mechanics of cutting approach - A step towards a house of predictive performance models for machining operations

This paper presents the series of on-going investigations, which led to the development of the 'Unified-Generalized Mechanics of Cutting Approach' to predictive modelling of various technological performance measures for the wide spectrum of machining operations used in practice. It is shown that this approach involved the development of generalized mechanics of cutting analyses of the cutting processes for machining with single edge and multiedge (form) tools and the establishment of a generic database of basic cutting quantities and edge force coefficients. This was followed by the development of a methodology for modelling each machining operation used in practice, based on the generalized cutting analyses and database. The models developed for turning, drilling and milling operations as well as machining with form tools and the novel rotary tool turning operations are briefly described together with recent research on predictive modelling of ball end-milling and machine tapping operations. It is shown that the models for the different machining operations could be 'unified' into a modular computer application structure, drawing on the generic cutting analyses and database. This 'unified' approach could represent a step towards the development of a 'House of Predictive Models' sought by the CIRP Working Group on modelling of machining operations. The considerable scope for further research is discussed in this paper.