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Operational Cutting Force Identification in End Milling Using Inverse Technique to Predict the Fatigue Tool Life

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Iranian Journal of Science and Technology, Transactions of Mechanical Engineering Aims and scope Submit manuscript

Abstract

The assessment of actual cutting forces is vital and essential task for the design and analysis of structural systems. The present study deals with experimental investigation of cutting forces during machining, considering the initial impact during the engagement of cutting tool and work piece. The cutting forces are studied on HSS tool and carbon steel work piece for various cutting parameters. Cutting force assessment directly during machining is a complex task, while the responses because of these forces can be measured using a sensor. The impact cutting force identification on end mill tool is investigated using inverse technique with the aid of frequency response function which measures the structural responses. Experimentally predicted cutting forces are compared with analytically determined cutting forces. Finite element analysis of end mill tool is conceded subjected to the cutting forces to estimate the induced stress, and using induced stress the fatigue life of end mill tool is predicted. The results show that experimental cutting forces predicted are in close agreement with the analytically determined cutting forces. The significance level of the experimental method is 99% having 1% error. Impact effect of cutting forces observed is in the range of 1.093–1.409 than the average cutting force. Cutting tools designed using average cutting force provides false picture of tool life and must be predicted using actual cutting forces.

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Authors and Affiliations

  1. Jain College of Engineering, Belgaum, India

    Ratan A. Patil

  2. KLS’ Gogte Institute of Technology, Belgaum, India

    Shrinivas L. Gombi

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  1. Ratan A. Patil
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  2. Shrinivas L. Gombi
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Correspondence to Ratan A. Patil.

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Patil, R.A., Gombi, S.L. Operational Cutting Force Identification in End Milling Using Inverse Technique to Predict the Fatigue Tool Life. Iran J Sci Technol Trans Mech Eng 46, 31–41 (2022). https://doi.org/10.1007/s40997-020-00388-z

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  • DOI: https://doi.org/10.1007/s40997-020-00388-z

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