Chip Flow Research Articles

MATHEMATICAL MODELS OF CUTTING FORCES IN TURNING OPERATIONS

The paper considers a variant of the predictive determination of the cutting force components for non-free cutting when turning. It is established that both the process of plastic deformation and the process of friction on back surfaces adjacent to main and auxiliary cutting edges of the tool influence the magnitude and direction of a cutting force component. The resulting force is defined as the vector sum of the forces that occur on the main and auxiliary cutting edges. We propose to determine the cutting force direction in non-free cutting as a vector in the direction of chip flow relative to the main cutting edge. The cutting process photography fixes the inclination angle of the chip flow. It is confirmed that in free cutting, the direction of chip flow is perpendicular to the main cutting edge. Contour turning on CNC lathes is accompanied by a change in the direction of feed motion resulting in a change in the main and auxiliary kinematic angles of the cutting tool. An increase in the active length of the main cutting edge in this situation leads to an increase in the contact area of the back surface of the main cutting edge with the workpiece surface, and, consequently, to an increase in the friction component of force, acting on the main cutting edge. Experimental measurement of the cutting force components makes it possible to determine the degree of influence of the force components associated with both the process of plastic deformation of the work material and the process of friction on the back surfaces adjacent to the main and auxiliary cutting edges of the tool. The obtained analytical dependences express the functional relationship between the elements of the cutting modes, the geometric parameters of the cutters, the degree of wear, the shape of the workpiece surface, and physical and mechanical properties of the work material. A large set of parameters included in the formulas for determining the components of the cutting force allows adequate monitoring the nature of the force interaction of the elements in the technological system when processing parts.

Degradation of multi-layer CVD-coated cemented carbide in finish milling compacted graphite iron

Stricter regulations on emissions and higher demands on engine performance drive automotive industries to replace conventional gray cast iron with compacted graphite iron (CGI). CGI has a higher wear resistance, strength, elastic modulus, and almost double fatigue strength as to gray cast iron, yet the same positive properties make CGI more difficult to machine. This study focuses on finish milling CGI EN-GJV-450 with current industrial standard of tooling: cemented carbide with multi-layer CVD-coating of Ti(C,N)–Al2O3. At cutting speed of 150 m/min a total of 3126 cm3 of material after 190 passes was removed, while 1645 cm3 was removed after 100 passes in case of 250 m/min. Studying the wear evolution at different engagement times demonstrated an accelerated chemical wear of the Al2O3 top coating due to its reaction with MgO-containing inclusions that creates a softer reaction product of (Mg,Fe,Mn)Al2O4 spinel which is abraded and removed with the chip flow. Ti(C,N) coating layer experiences diffusional and mechanical (abrasion, debonding, micro-fracture) wear mechanisms. Exposure of cemented carbide substrate resulted in its rapid wear in the form of cratering and massive material loss on the flank where the latter eventually causes tool failure. The adherence of CGI to WC-Co facilitates diffusional loss of carbon and tungsten from WC grains. Carbon reacts with iron at the interface forming iron carbide, while residual tungsten alloys it thus forming (Fex,W1-x)3C. This phase can reduce the wear rate as it acts as a diffusion barrier, but its high brittleness enables its periodic removal by adhesive wear. Outward cobalt diffusion was also an active wear mechanism that facilitates further diffusion of carbon and tungsten but also weakens the WC-grain bonding, further facilitating adhesive wear by CGI flow. Deposition of oxide inclusions to exposed WC-Co work as an anti-stick for CGI adhesion and thus reduces the wear rate.

Estimation of temperature in the cutting area during orthogonal turning of grade 2 titanium

The authors introduce an experimental-analytical method for determining the average temperature values in the PSZ (primary shear zone) and the SSZ (secondary shear zone) during orthogonal turning of grade 2 titanium with a use of an uncoated carbide tool with a positive rake angle and a flat rake face. The presented method is based on an algorithm in which the values of shear stress in the PSZ and the SSZ are calculated by means of the Johnson–Cook constitutive equation and Oxley’s model of cutting mechanics. Average temperature values in the PSZ and the SSZ are determined by iteratively finding the minimum difference between the calculated stress values. As its inputs, the algorithm uses the values of the feed and the tangential cutting force components, the value of chip flow velocity on the rake face, and the constants of the Johnson–Cook constitutive equation. The model was validated with a use of empirical data collected during the experiments. The test rig consisted of a KNUTH Masterturn 400 precision lathe equipped with a dynamometer, a high-speed camera, and a thermal imaging camera.

МАТЕМАТИЧЕСКИЕ МОДЕЛИ СИЛ РЕЗАНИЯ ПРИ ТОЧЕНИИ

This paper considers the predictive determination of the cutting force components for non-free cutting during turning. It has been established that plastic deformation and friction along the rear surfaces adjacent to the main and auxiliary cutting edges of the tool influence the magnitude and direction of the action of the component . The resulting force is defined as the vector sum of the forces that occur on the main and auxiliary cutting edges. The authors propose to determine the direction of the force in non-free cutting as a vector in the chip flow direction relative to the main cutting edge. The chip deviation angle was fixed by photographing the cutting process. The authors confirmed that in free cutting, the chip flow direction is perpendicular to the main cutting edge. The machining of shaped surfaces on lathes with numeric control systems is accompanied by changes in the feed movement direction and, as a result, changes in the kinematic main and auxiliary angles in the plan of the cutting tool. The increasing active length of the main cutting edge leads to an increase in the contact area of the rear surface of the main cutting edge with the machinable surface, and, consequently, an increase in the force component . The experimental measurement of the cutting force components allowed the determination of the impact degree of the force components connected both to the plastic deformation of the machinable material and to the friction on the rear surfaces adjacent to the main and auxiliary cutting edges of the tool. The analytical dependencies express the functional relationship between the elements of cutting modes, the geometric parameters of the cutters, the degree of wear, the shape of the machinable surface, and the physical and mechanical properties of the machinable material. A large set of parameters included in the formulas for determining the cutting force components allows the adequate monitoring the nature of the force interaction of the technological system elements during machining.

Theoretical and experimental research of edge inclination angle effect on minimum uncut chip thickness in oblique cutting of C45 steel

The minimum uncut chip thickness (MUCT) is an important phenomenon observed both in orthogonal and oblique cutting. Rounding the cutting edge influences the initiation of the cutting process and chip formation. In a previous study, the authors presented a theoretical analysis and experimental validation on the effect of edge inclination angle λs in the range of 0° to 60° on hmin in radial-free turning of C45 steel. The current work investigated the MUCT hmin in oblique cutting process of C45 steel, for extremely high value of edge inclination angle λs. In this research, a special technique based on milling tool machine using a special tool and sample is presented. Enabled model tests in the unprecedented range of angles λs not used in research to date. The samples were machined using a cutting speed vc = 0.063 m/min. Vertical feed of edge fv was determined by association on the applied sample slope (τ = 0.60–0.85 mm/m) and cutting speed vc. as fv = 37.8—53.5 μm/min. MUCT hmin parameter was measured using compensation for the effects of deformation, based on profilogram analysis. The machining experiments were carried out using a tool with rn = 185 μm. It was found that in the range of angles of 50° ≤ λs ≤ 85°, the MUCT decreases from hmin = 12 μm for λs = 50° to hmin = 4 μm for λs = 85°. Increasing λs by 35° resulted in up to threefold reduction in MUCT. The analysis of the experimental results of hmin for the range of studied λs angle confirmed authors previously reported theory for extreme values of λs. In optimization procedure based on LSM, chip flow angle coefficient was determined as k = 0.75 and critical value of rake angle γcf = -64.8°. This feature provides prediction of results with great accuracy to experimental value. The findings from this study opens the possibility of developing new tools for finishing operations in the field of oblique cutting with high values of λs angle. In addition, the results introduce new area for research on improving the surface quality based on lowering the effect of MUCT on surface roughness and explaining some aspects related to surface wear in the friction process.

A NUMERICAL AND STATISTICAL APPROACH OF DRILLING PERFORMANCE ON MACHINING OF Ti–6Al–4V ALLOY

Drilling, which constitutes one third of the machining operations, is widely used in many areas of the manufacturing industry. Various difficulties are encountered in the drilling process since the chip is formed in a closed limited chip flows. These difficulties directly affect the output parameters such as energy consumption, surface quality, and cutting force. Therefore, it is necessary to determine the ideal processing parameters to achieve the best performance. However, experimental research on machining processes requires both a long time and a high cost. For these reasons, machining outputs can be estimated by conducting drilling simulations with the finite element method. In this study, the finite element method is used in order to investigate the influence of different cutting parameters and different helix angles on the power and thrust force of Ti–6Al–4V (grade 5) alloy that is commonly used in the aviation industry. The study selected three different cutting speeds, feed rates, and helix angles as the cutting parameters. The experimental design was made according to the response surface method (RSM) Box–Behnken design in the Design-Expert program. Drilling simulations were performed using the ThirdWave AdvantEdgeTM software. The lowest thrust force measured is 1241.39 N at 40° helix angle, 2000-rpm revolution rate, and 0.05-mm/rev feed rate, while the lowest power consumed is 765.025 W at 30° helix angle, 1500-rpm revolution rate, and 0.05-mm/rev feed rate. As a result, it was determined that the most effective parameter for power and thrust force was the feed rate.

Cutting Force in Peripheral Milling of Additively Manufactured Maraging Steel

Additively manufactured parts have recently been applied to products in aerospace, automobile, and tool industries in terms of design flexibility and material consumption with mechanical strength. Because the surfaces of additively manufactured parts are coarse, milling is conducted as a post-process to achieve fine surfaces within the specified tolerance. However, the microstructures and the mechanical properties of additively manufactured metals differ from those of wrought metals. Therefore, the cutting characteristics should be understood to determine the appropriate cutting parameters. The paper studies the cutting process in peripheral milling of additively manufactured maraging steel in a cutting model. The cutting force, the surface finish, the chip morphology, and the tool wear were evaluated through cutting tests. Although the hardness of the additively manufactured workpiece was higher than that of the wrought workpiece, the maximum cutting forces were approximately the same. An energy-based force model was applied to discuss the cutting force characteristics in terms of the shear area and the shear stress on the shear plane. In milling of additively manufactured workpiece, the shear stress on the shear plane becomes larger than that of the wrought workpiece. However, the shear plane length is short at a large shear angle. Therefore, the cutting force does not significantly increase. The typical change in the cutting force of the additively manufactured workpiece is also compared with that of the wrought workpiece in terms of the cutting model. The chip flow directions, then, are analyzed in the cutting force model. The chips of the additively manufactured workpiece flow more in the radial direction than those of the wrought workpiece.

Analysis of diamond wear morphology and segment wear evolution during the process of hard granite sawing

Diamond circular sawblade has been widely used in hard granite processing. In this study, the wear mechanism and wear evolution of the diamond segment were investigated. The wear morphologies of diamond grits were classified as emerging diamond, whole diamond, crack diamond, blunt diamond, micro-fractured diamond, macro-fractured diamond, wear flat diamond, and pull-out diamond, which is based on sufficient observation data. The main form of diamond wear is fracture. The fracture morphology of diamond grit dominates by cleavage, which is brittle transgranular fractures, and the microscopic features are fracture steps and river-like patterns. Since the {111} crystal plane has the largest interplanar spacing among all the crystal planes, cleavage fractures tend to occur on this crystal plane. Through the scratches and pitting on the diamond grit surface, it proved that the wear process is a mixed type of two-body wear and three-body wear. However, some diamond grits exhibit special fracture morphology and are without the typical characteristics of cleavage fracture. Combined with internal factors (including microstructures and internal defect) and external factors (including chip flow, thermal load and mechanical load), the mechanism of various diamond wear morphologies and segment wear phenomena observed in the sawing experiment is clarified. Finally, the evolution process of the diamond failure and segment wear are described. The research systematically revealed the mechanism of segment wear and the fracture morphology characteristics of diamond grits in the sawing granites, which can further improve the understanding of segment wear and provide theoretical guidance for segment design.

Improved chip control on PCD tools by positioning of brazed chip breakers

A brazed chip breaker capable of controlling the chip curling and flow is proposed on the rake face of a polycrystalline diamond (PCD) tool to obtain ideal chip shape of aluminum alloy materials. Two new position parameters, the breaker-point distance and the rotation angle of chip breaker, are proposed for positioning the chip breaker on the rake face of PCD turning tool. Influences of two position parameters of the chip breaker on the chip curling and chip flow direction are studied through finite element simulations and cutting experiments. The appropriate breaker-point distance can improve the up-curling and back-flow of the chip, and control the chips flow to the tool flank face to form a C-shaped chip. After setting the appropriate breaker-point distance, increasing the rotation angle of chip breaker can promote the trend of side-curling and side-flow of the chip, which is beneficial to the formation of short helical chip. Based on the chip-breaking criterion and the geometric relationship between the chip breaker and tool rake face, the equations of two position parameters of chip breaker are established, and effective chip breaking can be achieved within the reasonable range of chip breaker position parameters calculated by the established equations. The proposed chip breaker which position parameters are convenient to measure and install can be brazed on turning and drilling tools to obtain needed chip shape of aluminum alloy materials. • Proposed two position parameters of chip breaker for PCD turning tools. • Derived a set of equations to determine the effective range of the two position parameters. • Analyzed the influence of the position parameters on the chip curl, chip flow direction and chip shape.

Geometric Modeling of Serrated Cutters for Endmilling Forces using Local Oblique Cutting and Rake Normal Correspondence

For nonstandard endmills with sinusoidal and circular serrations on nominally helical cutting edges, the edge space curve was subdivided into straight edge elements for constant increments of arc length. To calculate the local normal rake angle at the serrated edge point, Local Rake Normal Correspondence used the normal vector on the rake face of the corresponding unserrated helical edge point at the same axial cross section. Uncut chip thickness h was computed under Local Oblique Cutting Correspondence published earlier. Stabler’s rule specified chip flow direction and Lazoglu mechanistic normal and friction force coefficients completed the straight edge cutting element forces. Local force contribution vectors summed over the tool engagement resulted in global tool forces. Number of straight edge element computations were minimized with the hypotheses (a) cutting predominantly occurs at the vicinity of serration tips and (b) only the stock surfaces swept by flutes immediately prior and following the current flute need be considered for h. Interaction of axial cross sections at a significant fraction of the serration wavelength was noted. Thus, treating tool axial subdivisions in relative isolation for h is untenable. However, local normal rake angle on the serrated edges followed earlier published trends. For a square endmill, sinusoidally serrated, cutting with low axial depth of cut ADOC, modeled forces showed idle periods and unbalance fluctuations during a full rotation, but not the data; modeled forces for an identical unserrated helical cutter were lower than the serrated. For the same endmill with circular serrations cutting at high ADOC, no idle periods or unbalance were predicted and the agreement with published data was better.

Determination of the yield strength and the energy distribution in the milling of Inconel 718 considering fracture toughness

This article presents an analytical method to determine the yield strength and the energy distribution in the milling process of nickel alloy Inconel 718 by incorporating the fracture toughness, the plastic deformation and the friction effect. To study the geometry and mechanics in the oblique cutting process, mathematical analyses are done to derive the angles related to the friction (λ, λn), the shear flow (δ, ϕn) and the chip flow (β). Geometrical model for the serrated chip formation is established to derive the equations that are needed for calculating the fundamental quantities such as forces, velocities and shear strains. Then, the workpiece material's cutting yield strength and fracture toughness are predicted, and efforts also focus on characterizing and classifying the geometrical relationships among the uncut chip thickness, the actual feed rate and the instantaneous radial depth of cut. Equations to calculate the work in relation to the plastic flow, friction and material fracture are established, and subsequently, energy distribution for the serrated chip formation is evaluated from the cutting data. The proposed method has the advantages of convenience, feasibility and generality, compared with the standard tensile tests and the standard fracture mechanical tests, which are usually used to measure the material properties under static loadings or at a range of temperatures and loading rates. A series of milling tests have verified the method.

Multiobjective Optimization for Heat Transfer Performance of Micro-Fins and Signal Integrity of Key Interconnect Technologies in 3-D Integrated Chips

This article is devoted to the synergistic design of the thermal management and signal integrity for 3-D integrated chips. The structure parameters of the micro-fin and interconnected components are optimized to obtain a balanced performance of chip heat dissipation and signal integrity. The 3-D integrated chip flows heat transfer model under the action of electrothermal coupling is developed. A full-wave electromagnetic simulation model of the signal interconnection components is proposed with the same structural parameters. The effects of various structural factors on the heat transfer performance and signal integrity of 3-D integrated chips are investigated. A multiobjective optimization algorithm is carried out to simultaneously reduce the total thermal resistance of the 3-D integrated chip and the signal transmission losses of the critical interconnect components. The results show that the total thermal resistance of the 3-D IC becomes lower with a larger through-silicon via (TSV) diameter, micro-fins height and micro-fin radius, and smaller oxide thickness. When the TSV diameter and oxide thickness increase, the height and radius of the micro-fins are reduced to facilitate the signal transmission of the chip’s interconnected components. The response surface analysis method was used to design the experimental combination and thus obtain the fit function for the performance of the two objectives. Hundred sets of Pareto optimal solutions are obtained by multiobjective optimization. The technique for order preference by similarity to ideal solution (TOPSIS) method is used to select the weights of the two optimization objectives to determine the optimal solution. When thermal resistance and signal transmission are given equal weight in the chip design, thermal resistance is reduced by 13.8%, and signal transmission efficiency is improved by 9.74%. The study has important implications for chip thermal management and signal integrity.

Cutting Force in Drilling with Flat Bottom Drill

Flat bottom drills at a point angle of 180 deg. have recently been applied to not only drilling on inclined surfaces but also flat bottom holes in terms of the dimensional accuracy and the process efficiency. Controlling the cutting force, the tool damage, and the surface finish, the corner shape is a critical parameter in the design of the flat bottom drill. The paper discusses the effect of the corner radius on the cutting forces and the surface finish in drilling with flat bottom drills. The typical differences in the cutting force are confirmed during the edge engagement. Then, the cutting force is simulated with a chip flow model, in which the chip flow angle is determined to minimize the cutting energy. The cylinder surface finishes and the burr formations are associated with the chip flow direction and the uncut chip thickness at the end of the lip.

Evaluation of the cutting performance of micro-groove-textured PCD tool on SiCp/Al composites

The cutting performance of textured polycrystalline diamond (PCD) tools on SiCp/Al composites is studied using an orthogonal cutting experiment. Micro-grooves with rounded corners are machined on the tool. Two texture parameters, namely the distance between the texture and main cutting edge and the texture spacing, were varied to investigate their influence on the cutting performance. The former is found to play a more important role in machining. Compared with non-textured tools, textured tools reduce the cutting force and tool wear, improve the surface quality, and change the chip flow direction to produce an anti-adhesion effect during cutting. To elucidate the cutting mechanism of textured tools, the cutting performance of tools with different micro-groove shapes is numerically studied using the finite element method. The simulation results indicate that a micro-groove-textured PCD tool with rounded corners reduces the interaction between the tool texture and chips, and the particles in the interface play a supportive and rolling role between the chip and tool surface.

Preparation of Micro-Pit-Textured PCD Tools and Micro-Turning Experiment on SiCp/Al Composites.

Serious tool wear occurs very often during machining due to the reinforcing phases in the workpiece. In this study, micro-pit-textures were prepared on the surfaces of PCD tools with a nanosecond laser to improve their cutting performance on SiCp/Al composites. The micro-pits were designed with rounded corners to improve the chip flow. The location and size of the texture were determined by analyzing the tool-chip contact area of the non-textured tool. The cutting performance of these textured PCD tools was investigated through orthogonal cutting experiments. It was found that the optimal cutting performance of the textured tools was achieved with the proper distance of the texture from the main cutting edge (35 μm) and the pit spacing (60 μm), aa a result of which the main cutting force reduced by about 14%, and the tool wear and surface adhesion significantly reduced. This texture was then applied in the micro-turning experiments of the PCD tool on the SiCp/Al composites. The cutting force in this experiment reduced by 22%, and the textured tool provided better chip transfer and tool anti-tipping. In this study, the role of SiC particles as a third body between the tool and the chip surface is discussed.

Durability of micro diamond tools with different crystallographic planes

Micro diamond tools are indispensable for machining microstructured arrays. The cutting edge durability and consistency of micro diamond tools are the determinants of the microstructure quality and accuracy, in addition to the motion accuracy of the machine tool. A strength distribution model of the working area including the cutting edge and rake and flank faces was established considering diamond anisotropy and chip flow direction. Comprehensive wear resistances of micro diamond tools with different crystal orientation combinations were analyzed based on the model, and the wear prone areas of different tools were successfully predicted. The evolution processes of the sharpness and wear topography were monitored for every micro diamond tool in the micromachining experiments. The morphologies, profile errors and topological characteristic of the microstructures machined with different micro diamond tools with increasing cutting distance were analyzed. Finally, a conclusion was drawn that the wear resistances of the micro diamond tools in ascending order are Aγ{100}Aα{100}, Aγ{100}Aα{110}, Aγ{110}Aα{100}, and Aγ{110}Aα{110}. The three working areas of the Aγ{100}Aα{100} tool are prone to wear; in contrast, those of the Aγ{110}Aα{110}tool are resistant to wear. The tool wear of Aγ{100}Aα{110}is caused by flank face wear, and that of Aγ{110}Aα{100} is caused by rake face wear.

Schmid factor analysis for chip flow induced plastic deformation of textured cubic carbonitride coatings

In high-speed metal machining, cutting tools in the form of cemented carbide inserts coated with thin wear-resistant coatings are commonly used. These coatings are often made of metal carbonitrides with cubic rock salt crystal structure and different growth textures. However, the influence of the crystallographic texture of the coatings on their wear by plastic deformation due to the chip flow during machining needs to be revealed further. In this work, in order to analyse the ability of polycrystalline fibre-textured coatings with a rock salt structure to undergo plastic deformation, a method was developed for calculating Schmid factors of such textured coatings as a function of the loading angle of an external force. The Schmid factors were calculated for coatings with 100 and 211 growth textures, and {100} <110>, {110}<110> and {111}<110> as possible slip systems. For the {111}<110> slip systems, the Schmid factors are not much influenced by the force angle and coating texture, which is contrary to the {100}<110> and {110}<110> slip systems. The simulations were compared to wear on the rake face of two textured Ti(C,N) coatings after short longitudinal turning tests. The variation of the degree of plastic deformation of Ti(C,N) coatings with growth texture and external force angle indicates that the dominant activated slip systems are {110}<110> using the machining conditions applied in this work.

Tribological aspects of tool wear during turning Ti-15Mo alloy with cemented tungsten carbide cutting inserts prepared with different surface finishes

Due to the low machinability of titanium alloys, which have been increasingly applied in medical and aerospace industries, several studies have been carried out focusing on the improvement of tool life in machining processes that involve such class of material. Aiming at contributing to the technological investigations and at expanding the knowledge on the phenomena involved in the tool-workpiece contact, this work presents tool wear results and a tribological analysis of the application of cemented tungsten carbide cutting inserts with different roughness characteristics in the edge and flank face as well as grinding marks (grooves) in the rake face in distinct directions. The inserts were prepared by plunge-face grinding and used in turning of a beta-titanium alloy (Ti-15Mo). Results showed that the insert with lower surface and edge roughness and with grooves in the rake face perpendicular to chip flow direction led to the lowest final flank wear value when the tool life criterion was achieved. Higher flank wear values were obtained for the rougher inserts, due to the greater edge chipping produced in grinding.

Verification methodology of a multi-mode radiation-hard high-speed transceiver ASIC

The second version of Low Power Giga Bit Transceiver (lpGBTv1) addresses the functional and radiation-related issues discovered during the testing of lpGBTv0 prototype. Considerable changes to the chip configuration architecture and flow were required. The Universal Verification Methodology (UVM) based verification environment was extensively refactored to address the functional verification challenges posed by the architectural changes in the chip. Additionally, the new UVM environment was designed to support extensive verification of robustness to Single Event Effects (SEE). In this paper we present the revamped UVM verification framework of lpGBTv1 and discuss the verification process, tools, techniques and metrics used to sign-off the design before submission.

An analytical cutting force model of quasi-intermittent vibration assisted swing cutting based on predictive machining theory

Quasi-intermittent vibration assisted swing (QVASC) method was aimed to improve the cutting machinability of difficult-to-machine materials. Inherited the intermittent cutting characteristics of the elliptical vibration cutting (EVC) technology, this method reduces the impact of residual height on the machined surface quality. But there is still a lack of in-depth research on cutting force modeling of QVASC. Based on the conventional cutting force model, a cutting force prediction model in QVASC processing, which considers the time-variable characteristics of QVASC, adopts the non-equidistant shear zone model and regards the workpiece material properties, tool geometry, and cutting conditions as the input data are proposed in this paper. Using the micro-element method, the proposed model decomposed the cutting edge to calculate the cutting force and the cutting force value by superimposing them. It finally predicts the chip flow angle. Experimental results show that when the cutting velocity increases, the average cutting force and the Z -direction increases by 20%, the average cutting force and the Y direction decreases by 17%. The average cutting force along X direction remains unchanged; the depth of cutting became larger. Besides, the average cutting force X decreased by 18%, Y decreased 21%, and Z increased by 13%. As the feed rate increases, the X direction is increased by 26%, and the Z direction is reduced by 22%, while the cutting force in the Y direction is unchanged. After comparing and verifying the measured value and the predicted value, the minimum error of the prediction model reaches 4.01%, which validates the force model of QVACS.