Cutting Force Modeling: Genesis, State of the Art, and Development

The chapter gives a historical prospective of the origin and developments of empirical equations for cutting forceCutting force in the manner never presented before. It is shown that the Wiebe formula published in 1858 is still in wide use today in many research and practical applications including cutting tool manufacturersTool manufacturers’ technical guides/catalogs. The chapter analyses the historical development of the formula for the cutting force from 1858 to the preset. The foundation of the so-called mechanistic approachMechanistic approach in metal cutting is considered. It is discussed that there are actually two considerably different mechanistic approachesMechanistic approach used today. Although both include the use of the cutting forceCutting force coefficient, the way these coefficients are determined through numerous cutting tests are considerably different. The origin, essence, and drawbacks of both approaches are analyzed in great details. The chapter argues that no further progress in meatal cutting in terms of increasing its efficiency can be made if the known approach are used. The chapter suggests that at present stage of development, finite element method (FEM) modeling is one of feasible alternative to pure experimental studies in metal cutting. The problems to be addressed in FEM simulation in metal cutting as the proper model of metal cutting, relevant constitutive model of work material behavior, and contact conditions at the chip-rake face and workpiece-flank face interfaces are revealed and the feasible ways of their resolution are suggested discussed.