Force modelling for cylindrical plunge cutting

This paper describes the development of an analytical model for the cutting forces in multiblade plunge cutting of cylindrical parts. The development uses the relationship between the instantaneous chip area and the local cutting forces at each individual blade to formulate the total resultant forces via kinematic integration along the cutting edges. The model expresses the cutting forces in explicit terms of part material properties, cutter geometry, part geometry, and cutting conditions. Experiments were performed under various cutting conditions to verify the fidelity of the model at different stages of cutter-part engagement. The waveform and amplitude characteristics of the model-predicted forces agree closely with the measurement. The model can facilitate tool geometry design and cutting condition planning in light of the optimisation of cutting forces.