5 Cutting Forces

5.1 Introduction R mat

During cutting process, the workpiece material
Rfr
opposes the penetration of tool wedge, (cutting
resistance R). This is caused by:
Rmat …. Resistance against failure of cohesion
of material molecules.
Rel + Rpl …. Resistance against elastic and
plastic deformations.
(Rel + Rpl)
Rfr …. Resistance against external friction workpiece
between the chip and tool surface and between
the tool and machined surface.
R  Rmat  Rel  Rpl   R fr
For cutting process, the tool must apply a force P which is equal to R. where P is the resultant
cutting force.

5.2 Components of cutting force in turning X

The three components are perpendicular to
Workpiece

t
each other where: n
PX … Axial force, parallel to the workpiece
Z
axis of rotation and opposing feed. P
X
P
PY … Radial force, in a horizontal plane and X Y
Y
perpendicular to the workpiece axis Tool

PZ … Tangential force, tangent to the P

Z
workpiece surface. s
(mm/rev) P
Resultant cutting force
Force system when oblique turning
P  PX 2  PY 2  pZ 2

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1. Tangential force PZ:
It is used for power determination and for tool design calculation
a) For calculation of required motor power
PZ  v
N eff  [kw]
60  1000
N eff
N mot 

where PZ
PZ …. Tangential force (N)
n
Neff … Effective power (kw)
Nmot … Motor power (kw)

h
W.P

v …… Cutting speed (m/min) b

 …… cutting efficiency of machine tool. L
b) For tool design calculation
Bending moment on tool cross-section MB is given by:
M b  PZ  L   b  Wb

PZ  L bh2
Wb  
b 6

where b is the bending strength of the tool material (MPa)

Wb is the bending modulus of section (mm3)

d h
h

b
h

d 3 h3 bh2
Wb  Wb  Wb 
32 6 6

2. Radial force PY:

This component affects workpiece deflection during
cutting and leads to workpiece vibration consequently
resulting in bad surface roughness Ra  and bad
accuracy IT . P

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3. Axial force
It influences mainly the required power of
feed mechanism.
P
s X
Approximately: PX = (0.2 - 0.3) PZ
PY = (0.4 – 0.5) PZ
5.3 Determination of cutting forces:
5.3.1 By measurements
1. Direct method: Mechanical force
dynamometer
Using dynamometers either mechanical or piezo- P (dial gauge)
Z
electrical crystal. The amount of deflection is
n PY

proportional to the value of force component. w.p.

P (dial gauge)
2. Indirect method: PZ Y

Using wattmeter to measure power input of the

electrical motor of the machine tool. The power is measured in two modes:
 When cutting, Ncut (kw).
 When idling, Nidle (kw) (without cutting).
PZ  v
N eff  N cut  N idle 
60  1000
N eff  60  1000
PZ 
v
5.3.2 By calculation
1. Specific cutting resistance:
The specific cutting resistance is defined as the work done for removing one unit volume of
chip material.
PZ
KS  (MPa)
st
The value of KS is given in technological tables for different workpiece materials and tools.
2. Power input to the electrical motor:
PZ  v
N eff  N mot   (kw)
60  1000
where:
Nmot …. Power input of electrical motor in kw.
 …. Efficiency of machine tool at a given process

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3. Using empirical equations:
X PX YPX
PX  C PX .t .s

X PY YPY
PY  C PY .t .s

X PZ YPZ
PX  C PZ .t .s

where:
All constants and exponents are given in technological tables according to workpiece
material, tool and cutting conditions.
Experimental determination of empirical equations
I. At constant depth of cut: t = to change feed (s) and measure P (PX, PY and PZ).

P  C P .t X P .sYP P
at t = to

P  C P .t o X P .s YP tan = YP
1

P  C1 .sYP

1

log P  log C1  YP log s log-log scale
s
It is a straight line (using log scale). YP can be
determined from the graph.

II. At constant feed: s=so change depth of cut t

and measure P. P
P  C P .t X P .so YP

P  C2 .t X P tan =
2 XP
2

log P  log C2  X P log t

log-log scale
XP can be determined from the graph. Then CP is
t
determined using any point on graph of known
values of s and t.

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5.4 Factors affecting cutting forces
1. Workpiece material:  , HB  P 


2. Cutting conditions:

P P
Z Z


B.U.E     PZ


v 
   , def.  P 
Z

B.U.E

s ,t 25 50 100 150 v
3. Tool geometry
P P
Z Z

 
 difficult penetration  PZ    easy penetration  PZ

P
Z P PX = Pn sin  1 PY = Pn cos  2
Z
PX PX PX


2
1

Pn
Pn PY
PY

PY

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