PST

CUTTING FORCES

Motivation

Force measurement in metal cutting is

essential requirement as it is related to
machine part design, tool design, power
consumptions, vibrations, part accuracy, etc.
It is the purpose of the measurement of
cutting force to be able to understand the
cutting mechanism such as the effects of
cutting variables on the cutting force, the
machinability of the work piece, the process
of chip formation, chatter, and tool wear

Motivation

Knowledge
of
cutting forces is
very important ?
Design

of
the
cutting tools
Design
of
the
fixtures
Calculation of the
machine tool power
Selection
of
the
cutting conditions

Components of Cutting
Forces in Orthogonal Cutting

Total cutting force F is

conveniently resolved
into two components
in the horizontal and
vertical direction
Can
be
directly
measured using a
force
measuring
device
called
a
dynamometer
The force components
act against the tool

Horizontal Force
Component

Cutting force FC : this

force is in the direction
of primary motion
The
cutting
force
constitutes
about
70~80 % of the total
force F
Used to calculate the
power P required to
perform the machining
operation, P = VFC

Vertical Force
Component
Thrust force FD:
this force is in
direction of feed
motion
in
orthogonal cutting
The thrust force is
used to calculate
the power of feed
motion

Forces in Oblique Cutting:

Turning Operation
In
threedimensional
oblique
cutting,
one more force
component
appears along the
third axis
The thrust force FD
is further resolved
into
two
more
components

Controlling Cutting
Forces
The

cutting force value is primarily

affected by
cutting conditions (cutting speed V, feed

f, depth of cut d)
cutting tool geometry (tool orthogonal
rake angle)
properties of work material
The

simplest way to control cutting

forces is to change the cutting
conditions

Effect of Operating
Conditions on Cutting Forces

Most effective method of force control is to change d

and f
If for some reasons change of the cutting conditions is
not justified, machining with positive tool orthogonal rake
angles will decrease significantly the cutting force but at

Dynamometers

FORCE MEASUREMENT

Orthogonal Cutting Forces

that cannot be measured

Orthogonal Cutting Forces

that can be measured

Measurement of Cutting
Forces
The

cutting forces developed in

machining
operations
may
be
estimated
Indirectly

by

obtaining

the

power

consumed
Directly
from
metal
cutting
dynamometers; mechanical, hydraulic,
and pneumatic or several types of
electro-mechanical dynamometers

Principles of Cutting Force(s)

Measurement
Three

basic principles :

Measurement of elastic deflection of a body

subjected to the cutting force

Measurement of elastic deformation, i.e.
strain induced by the force
Measurement of pressure developed in a
medium by the force.
The

type of the transducer depends

upon how that deflection, strain or
pressure is detected and quantified

Measuring deflection caused

by the cutting force(s)

Since for a given cutting tool and its holder, E

and I are fixed
Pz

Measuring cutting force by monitoring

elastic strain caused by the force

Strain Gauge Bridge

Connection

Measuring cutting forces by

pressure caused by the force

Lathe Tool Dynamometer

CALIBRATION of
Dynamometers
The

strain gauges are arranged in

the dynamometer such that
Four strain gauges will form a bridge for

measuring the horizontal component in

the feed direction, while
The other strain gauges form a bridge
for measuring the vertical component in
the cutting direction
The

outputs of the Wheatstone

bridges are connected to a multichannel, digital strain
measuring

Calibration Setup

Cutting
force

Thrust force

Obsevations
D v (ch1)

Reading (prove)

Dh (ch2)

Reading (prove)

20

23

11

42

10

42

16

62

14

59

20

79

19

79

26

103

25

102

31

121

30

124

35

138

34

148

42

161

36

165

49

190

40

184

53

208

42

208

Calibration Curves

SLOPE =3.89051

SLOPE=4.858552

Fv= 16.727 x Dv = Fv (N) ; Fh= 20.898 x Dh = Fh (N

EXPERIMENT

Before cutting operation,

the two bridges are
adjusted
and
zero
balanced
As
cutting
operation
starts, a load is applied
through the tool to the
dynamometer
Bridge
readings
corresponding to the
forces
Fv
and
Fh
respectively
are
recorded for different
cutting conditions

d (mm)

V (m/min)
66

0.5

98

132

66

1.5

98

132

66

f
(mm/
rev)

Dy

Dh

Fv (N)

Fh (N)

0.102

16

13

267.632

271.674

0.205

17

17

284.359

355.266

0.304

17

20

284.359

417.96

0.102

15

12

250.905

250.776

0.205

16

17

267.632

355.266

0.304

17

18

284.359

376.164

0.102

13

12

217.451

250.776

0.205

15

14

250.905

292.572

0.304

16

16

267.632

334.368

0.102

27

22

451.629

459.756

0.205

32

32

535.264

668.736

0.304

36

36

602.172

752.328

0.102

26

21

434.902

438.858

0.205

32

30

535.264

626.94

0.304

35

35

585.445

731.43

0.102

25

20

418.175

417.96

0.205

32

29

535.264

606.042

0.304

34

33

568.718

689.634

0.102

47

35

786.169

731.43

0.205

49

47

819.623

982.206

0.304

65

65

1087.255

1358.37

0.102

43

34

719.261

710.532

Variation of Thrust force

Variation of Main cutting force