Using of least square and fuzzy logic methods to estimate the cutting forces for a new tool in machining of SAE 4140

In this paper, analytical-empirical and fuzzy logic-based models were created to predict the cutting forces in turning process for a new tool. A dynamometer that measure static cutting forces was used for measuring the forces. AISI 4140 steel was used as the work piece material for conducting the experiments due to its most common applications in machining process industry. Cutting force, thrust force and radial force were measured for three combinations of cutting speeds (V), cutting feeds (f) and cutting depths (d). Full factorial method was used to design the experiments. For developing the analytical model, the least square (LS) method was used to estimate the model constants. Experimental results were compared with the predicted results for both of the developed models. The comparing results show the efficiency of the both developed models. However, the results confirm that the accuracy of the fuzzy model is much higher than the analytical model in prediction of the cutting forces. [Submitted 30 May 2017; Accepted 26 May 2018]