Comparison and Selection of Modeling Methods for Material Removal Power in Cylindrical Turning

Cylindrical turning, as one of the most common machining methods in mechanical processing, accurately evaluating the power during the material removal process in cylindrical turning is a prerequisite and foundation for achieving energy optimization in mechanical machining processes. Currently, there are three main modeling methods for the material removal power in cylindrical turning: First, calculating the material removal power through the specific energy of cutting per unit volume (Method I); Second, calculating the material removal power through cutting forces (Method II); Third, calculating the material removal power through power measurement combined with statistical analysis (Method III). However, there is currently no general agreement on the effectiveness and applicability of these three modeling methods. Therefore, the purpose of this study is to compare and evaluate these three modeling methods through cylindrical turning experiments. The experimental results indicate that Method II has the smallest prediction error, with an average error of 4.91%. Method III follows with prediction errors all below 8.57%. Method I has the largest prediction error, with the maximum error reaching 31.09%.