1. What is Cutting Force in Milling?

Definition: Cutting force (F_c) is the tangential force acting on the cutting tool during milling operations.

Purpose: This calculation helps engineers determine the power requirements, tool selection, and machine stability for milling processes.

2. How Does the Calculator Work?

The calculator uses the formula:

Where:

• \( F_c \) — Cutting force (Newtons)
• \( a_e \) — Radial depth of cut (meters)
• \( a_p \) — Axial depth of cut (meters)
• \( K_c \) — Specific cutting force (N/m²)
• \( d \) — Tool diameter (meters)

Explanation: The product of depths of cut and specific force is divided by tool diameter to get the tangential cutting force.

3. Importance of Cutting Force Calculation

Details: Proper force estimation ensures tool longevity, prevents machine overload, and helps achieve desired surface finish.

4. Using the Calculator

Tips: Enter the radial and axial depths of cut, specific cutting force (default 2000 N/m²), and tool diameter (default 0.01m). All values must be > 0.

5. Frequently Asked Questions (FAQ)

Q1: What is typical K_c value for steel?
A: For mild steel, K_c is typically 2000-3000 N/mm² (convert to N/m² by multiplying by 1e6).

Q2: How does tool diameter affect cutting force?
A: Larger diameter tools distribute the cutting force over a greater area, reducing the force per tooth.

Q3: What units should I use?
A: All length dimensions should be in meters (m) for consistent Newtons (N) output.

Q4: Does this account for multiple cutting teeth?
A: No, this calculates force per tooth. Multiply by number of teeth for total cutting force.

Q5: How do I find K_c for my material?
A: Consult machining handbooks or material supplier data sheets for specific values.