Dynamics of Metalcutting

A practical engineering method of calculating tangential cutting force in milling is proposed. The method is based on the ultimate tensile strength of a work material, cross-sectional area of uncut chip, the number of inserts in cut, and a machinability factor of a workpiece material. Milling tests of high shear cutters with torque dynamometer were carried out at a wide range of the cutting conditions and various workpiece materials to verify the concept. Proposed method provides the accuracy of ± 15% or better for calculating tangential cutting force, torque, and power consumption in relationship with machining conditions and work material mechanical properties.