A new procedure to determine instantaneous cutting force coefficients for machining force prediction

Abstract

This paper presents a new procedure to determine instantaneous cutting force coefficients which are required for process simulation by mechanistic modeling. This new procedure drastically reduces the number of experiments for calibration and improves the accuracy of dynamic cutting forces and force signatures by considering the size effects. Comparisons are shown to illustrate the effectiveness of the proposed method in determining the chip flow angle and those predicted by various existing analytical models. The importance of using instantaneous cutting force coefficients instead of conventional average coefficients is demonstrated through simulation based on the mechanistic models.