Theoretical and Experimental Analysis of the Effect of Chip Size Ratio on Cutting Forces in Face Milling of Steel

Abstract: In this paper, the effect of chip size ratio on the cutting forces in face milling of steel is investigated with both geometrical analysis and experimental work pertaining to the testing of various cutting conditions. More specifically, the focus is on the increase of the amount of material being removed in one pass at high cutting speed, in connection to the increase of the cutting forces; the former increase should be maximum while the latter should be kept to a minimum. For this purpose, five different values of feed are tested and cutting forces are measured by a dynamometer, on a xyz axes coordinate system attached to the workpiece. Furthermore, cutting force components, referring to a coordinate system attached on the tool edge, can be calculated through geometrical assumptions and mathematical formulation. It is concluded that an eight times increase in feed results in eight-fold increase of cutting force Fc while material removal is much higher.