Analytical modeling and prediction of cutting forces in orthogonal turning: a review

The knowledge of cutting forces in various machining processes is of great importance not only for the designer-manufacturer of machine tools, but also for the user, since the cutting force governs cutting heat generation, tool life, and machining accuracy. In this regard, lots of investigations have been conducted on the cutting forces by developing different types of prediction models to make appropriate estimations, which are grouped into the analytical, empirical, and numerical methods. This paper conducts a survey on the development of analytical cutting force models for the orthogonal turning/cutting process. The analytical force models developed from the shear theory are detailed reviewed, and other analytical modeling methods for specially-designed tools, advanced materials, and special kinematics are also presented. The modeling laws and key challenges are also discussed for future researches.