An examination of the fundamental mechanics of cutting force coefficients

• The cutting force coefficients in the average cutting force model are constants.
• A series of tests are performed to investigate the cutting force coefficients.
• The cutting force coefficients are not affected by milling parameters.
• The cutting force coefficients depend on the tool–workpiece material combination.
• This finding offers a theoretical basis for studying milling chatter.

In metal cutting, the cutting force is the key factor affecting the machined surface, and is also important in determining reasonable cutting parameters. The research and construction of cutting force prediction models therefore has a great practical value. The accuracy of cutting force prediction largely depends on the cutting force coefficients of the material. In the average cutting force model, cutting force coefficients are considered to be constant. This study makes use of experiments to investigate the cutting force coefficients in the average cutting force model, with a view to accurately identifying cutting force coefficients and verifying that they are related only to the tool–workpiece material couple and the tool geometrical parameters, and are not affected by milling parameters. To this end, the paper first examines the theory behind identifying cutting force coefficients in the average cutting force model. Based on this theory, a series of slot-milling experiments are performed to measure the milling forces, fixing spindle speeds and radial/axial depths of cutting, and linearly varying the feed per tooth. The tangential milling force coefficient and the radial milling force coefficient are then calculated by linearly fitting the experimental data. The obtained results show that altering the milling parameters does not change the milling force coefficients for the selected tool/workpiece material combination.

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