A comparison of experimental estimation methods of the ploughing force in orthogonal cutting

In micro-cutting, the determination of the ploughing forces is necessary for wear monitoring of the cutting tool. The aim of this research was to confirm that the extrapolation method on zero thickness cannot be used to determine the ploughing forces. This paper presents experimental measurement results of the ploughing forces in orthogonal cutting, obtained by different methods. The comparison of measurement results was carried out in chipping of aluminium alloys and using structural and stainless steels. It was found that the ploughing forces determined by the extrapolation method on zero thickness proved to be substantially greater than those determined by the comparison method of total forces at different flank wears.

► This paper presents values of the ploughing forces, obtained by different methods. ► The force determined by the extrapolation method is greater by a factor of 1.36–5.35. ► The measurement error cannot explain the discrepancy of the ploughing forces. ► The extrapolation method cannot be used to determine the ploughing forces.