A Methodology for Practical Cutting Force Evaluation Based on the Energy Spent in the Cutting System

& This paper presents a methodology for practical estimation of cutting force and cutting power. Based on a previously proposed definition, the power spent in metal cutting is the summation of four components: the power spent on the plastic deformation of the layer being removed by both major and minor cutting edges, the power spent on the tool-chip interface, the power spent on the tool-workpiece interface, and the power spent in the formation of new surfaces (cohesive energy). This paper provides a complete list of mathematical expressions needed for the calculation of each energy mode and demonstrates their utility for turning operation of two work materials: AISI bearing steel E52100 and aerospace aluminum alloy 2024 T6. The calculated cutting forces were in fairly good agreement with the experimental results. Energy partition in the cutting system and relative impact of the parameters of the machining regime are discussed. For the first time, a simple and practical method is available for the calculation of the total cutting power and the evaluation of the relative contributions of each individual component of the cutting system.