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1

Simulation-based optimization of machining forces in turning Inconel 718 employing the Johnson–Cook model

Zeqiri Fitim

Advances in Science and Technology. Research Journal

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2026

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Vol. 20, no. 8

236--241

EN

This study investigates the influence of cutting parameters on cutting forces during the turning of Inconel 718 using the finite element method (FEM). Numerical simulations were carried out with Deform 3D (V6.1) and validated against established theoretical models. The Johnson–Cook constitutive model was applied to describe the material behavior under high strain rates and elevated temperatures, while process optimization was performed using the Taguchi design of experiments (DOE) in Minitab 17. The results demonstrate that cutting speed, feed rate, and depth of cut significantly affect cutting forces in all three directions (Fx, Fy, Fz). Specifically, increasing cutting speed reduces cutting forces, whereas higher feed rates and depths of cut increase them. Furthermore, tool geometry—particularly tool nose radius—was found to influence tangential and radial forces while reducing axial forces. The proposed numerical model shows strong agreement with published experimental data, confirming the accuracy of FEM in predicting cutting forces during the machining of Inconel 718. These findings provide valuable insights for optimizing turning parameters, improving tool life, and ensuring machining efficiency in the processing of difficult-to-cut superalloys.

2

Full-Field Force Mapping of Cutting Forces Driven by Local Density Variations in Norway Spruce Wood

Mellqvist Daniel, Buck Dietrich, Johansson Jimmy

Annals of Warsaw University of Life Sciences - SGGW. Forestry and Wood Technology

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2025

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No. 131

44--53

EN

Full-Field Force Mapping of Cutting Forces Driven by Local Density Variations in Norway Spruce Wood. Local density variations in wood influence cutting performance. In this study, full-field force mapping was applied to investigate the relationship between density distribution and cutting forces. Cutting forces were measured using piezoelectric transducers during cutting of Norway spruce. X-ray computed tomography (CT) scans of the workpiece provided spatially resolved density data. Force maps were constructed by aligning recorded forces with kerf positions and CT data. Results showed that cutting forces increased in regions of higher density, particularly near knot boundaries and latewood zones. Inner knot areas exhibiting lower density correlated with reduced cutting forces. Normal-force patterns were less responsive to local density changes. No self-feeding behaviour was observed. The integrated CT–force mapping technique enables spatial analysis of cutting responses in relation to anatomical wood features.

3

Prediction and experimental validation of cutting forces in ball end milling of aluminum 7075-T6 alloy

Sifeddine Mekentichi, Benmohammed Brahim, Schlegel Daniel, Lee-Remond Sora, Benyoucef Ahmed

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 8

68--76

EN

This study presents the development and validation of a hybrid cutting force prediction model for ball end milling of aluminum 7075-T6 alloy. The model combines a mechanistic approach with a specific cutting force coefficient (Ks=850 N/mm²) sourced from experimental literature. Cutting forces in the x, y, and z directions are predicted by integrating differential force components with tool geometry and machining parameters. Experimental validation was performed under dry conditions at a spindle speed of 15,000 rpm. In the x-direction, the simulated force was 162.4 N versus an experimental force of 215.4 N; in the y and z-directions, predicted values (65.2 N and 25.3 N) closely matched experimental forces (74.3 N and 28.2 N), respectively. The corresponding mean absolute errors were 18.2% (x), 4.5% (y), and 3.3% (z). The higher error in the x direction highlights limitations in modeling tangential force dynamics, while the y and z predictions align closely with experimental data. Leveraging the experimentally derived Ks, the proposed model offers a practical tool for optimizing machining processes in the aerospace sector, with potential for further refinement in tangential force modeling.

4

Evaluation of the force meter accuracy in the engineering industry applications

Tomczyk Krzysztof, Kowalczyk Małgorzata, Gębarowski Tomasz, Felhő Csaba

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 10

65--79

EN

This paper presents an assessment of the force meter (dynamometer) dynamic accuracy applied in the engineering industry. This assessment was made by determining the dynamic error based on the absolute error criterion. The mathematical basis for determining the dynamometers error was presented, and the corresponding procedures were developed. The values of dynamometer parameters and associated uncertainties were determined, then they were compared with the values calculated in the corresponding datasheet and finally the relationship between the dynamic absolute error and the dynamometer parameters was presented. The solutions presented allow the easy and quick determination of the accuracy of the dynamometers, and first of all significantly an increase the reliability and safety of engineering systems which use these type of measuring devices. The upper bound of the dynamic error developed in the paper may constitute an additional comparative criterion in assessing the accuracy of dynamometers produced by different manufacturers. New achievement of this paper is the presentation of the relationship between the dynamic error expressed by using the absolute error criterion and the values of the parameters of the mathematical model of the dynamometer in terms of applications in the engineering industry. These relationships are presented using the corresponding mathematical functions as well as graphically using 3D graphs. The calculation results were obtained using MathCad 5.0 and MATLAB R2024.

5

Badania analityczne i eksperymentalne wibracyjnego krojenia bloków książkowych

Petriaszwili Georgij

Przemysł Chemiczny

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2024

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T. 103, nr 11

1331--1333

PL

Przedstawiono wyniki badań nowego sposobu wibracyjnego krojenia bloków książkowych nożem krążkowym ustawionym z niewielkim mimośrodem. Na podstawie analizy kinematyki wibracyjnego krojenia wykazano, że proces obróbki może odbywać się w dwóch trybach: krojenie nieprzerywane oraz krojenie przerywane (impulsowe). Opracowano model matematyczny i przeprowadzono komputerowe obliczenia siły wibracyjnego krojenia. Badania analityczne porównano z wynikami badań eksperymentalnych. Na podstawie badań ustalono, że największy wpływ na składowe siły krojenia bloków książkowych wywierają prędkość posuwu bloków, prędkość obrotowa noża i wielkość mimośrodu.

EN

A new method of vibratory cutting of book blocks using a circular knife set with a small eccentricity were presented. The processing process can take place in two modes: continuous cutting and intermittent (impulsive) cutting. A math. model was developed and computer calculations of the vibratory cutting force were performed. Anal. studies were compared with the results of exptl. studies conducted at a laboratory stand equipped with a special carriage-dynamometer, which, using a computer measuring system, enabled the recording of the cutting force components. The greatest impact on the components of the book block cutting force was exerted by the block feed speed, the knife rotational speed and the eccentricity value.

6

The Effect of Milling Parameters of Vanadis 4 Extra Steel on Cutting Force Values and Roughness of Machined Surface

Szajna Artur, Bazan Anna, Tymczyszyn Tymczyszyn, Kawalec Małgorzata, Rydzak Tomasz, Kubik Paweł

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no. 8

181--190

EN

The article presents the results of experimental studies of the milling process of Vanadis 4 Extra - tool steel 1.2210 with a four-flute AlCrN-coated end mill. On the basis of the measured values of the total cutting force F and the roughness parameters Ra and Rz of machined surfaces, the relationships between specified cutting parameters and the analyzed roughness parameters were determined. Regression model of cutting force F was developed considering statistically significant cutting parameters. The developed model was validated using an additional set of recorded force values. Regression models were also created for the roughness parameters Ra and Rz of machined surfaces but they were found to be too inaccurate for the prediction of the aforementioned texture parameters. After analysis of the results obtained, it was found that the cutting speed vc had no effect on the value of the total cutting force F, while its influence on the roughness parameters was noticeable. It was also shown that, of the technological parameters ap, ae and fz within the assumed ranges of variation, the depth of cut ap, has the greatest effect on the cutting force F, the width of cut ae and the feed rate fz have a smaller effect. It was also shown that in the case of low cutting speeds vc the parameter Ra of the machined surface roughness strongly depends on the depth of cut ap and width of cut ae. At the same time it was noticed an increase in the Rz parameter with decreasing cutting speed vc. The remaining technological parameters, however, also significantly affect the obtained values of the Rz roughness parameter measured on the machined surface.

7

Evaluation of the Influence of Tool Coatings on the Machinability of the Ti6Al4V Alloy Using Gray Relational Analysis

Karolczak Paweł, Adamczak Michał

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no. 6

13--28

EN

This paper presents a study of the turning of titanium alloy Ti6Al4V with uncoated and physically or chemically coated carbide blades. The indicators studied and measured were 3D surface roughness, cutting force, the shape of the resulting chips and the degree of blade wear. It was found that coating the cutting blades increased the cutting forces. More blade wear mechanisms also occur, including thermal and adhesive wear. The chemically applied coating makes it possible to obtain the best roughness of Sq and Sz. The coating of the cutting blades had no effect on the form of the chips produced. The Grey Relational Analysis (GRA) confirmed that the recommended blades for the machining of superalloys warranted better technological results for the machining Ti6Al4V alloy.

8

Evaluation of Structural Powder Steel Properties after High-Temperature Thermomechanical Treatment and Finish Turning

Leksycki Kamil, Feldshtein Eugene, Maruda Radosław, Dyachkova Larisa, Szczotkarz Natalia, Zverko Alexandra

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no. 1

26--35

EN

High-temperature thermo-mechanical processing (HTTMP) is a combination of plastic deformation and heat treatment operations. Such action makes it possible to increase metal mechanical properties resulting from both mechanical strengthening and heat treatment. As a result, it is possible to achieve high complex of operating characteristics of different types of steel and other alloys. However, there is a lack of information on the applicability of HTTMP of powder steel. These types of steel are very effective substitutes for traditional structural steel but are characterized by poor mechanical properties. This study considers the possibility of using HTTMP for powder steel frame additionally infiltrated by bronze with MoS2 addition to increase mechanical properties of the materials studied. Steel infiltrated, infiltrated and then hardened, infiltrated and then HTTMP treated with strain rates of 30, 50 and 70% were compared. The microstructural properties and hardness of the materials before machining were studied as well as the cutting forces and surface topography of those materials after turning with AH8015 carbide inserts. Cutting forces tests were realized with vc = 157 m/min, f = 0.25 mm/rev and ap = 0.25 mm. Surface topography tests were carried out with vc = 157 m/min, f = 0.25 mm/rev and ap = 0.25 mm. Constant cutting parameters were used to eliminate the effects of rest factors. It was found that the lowest cutting forces (Fc, Fp and Ff), surface roughness parameters (Sa and Sq) and small areas with single high peaks on the machined surface were obtained for infiltrated powder steel with subsequent HTTMP machining under 50% strain rate.

9

Analytical study on the cutting force and residual stress in whirlwind milling of a large screw

Guo Qin, Wang Yulin, Zhou Bin

Journal of Theoretical and Applied Mechanics

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2023

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Vol. 61 nr 1

65--76

EN

The finite element method (FEM) is developed to simulate a discontinuous cutting in the whirlwind milling. Firstly, a simplified arc-cutting model for simulating the actual circular cutting, and a plane-cutting model for simplification were both developed and verified by experiments. Then, the effects of cutting parameters on the cutting force and residual stress were effectively investigated based on the plane-cutting model. Moreover, a plane-second- -cutting model was further developed. It showed that a minor decrease of cutting force and a higher maximum compressive stress were generated in the second cutting. Those results were conducive to predict and improve the whirlwind milling.

10

Analysing the impact of cutting force and vibration on surface roughness in external cylindrical grinding of SKH2 steel

Hoang Long, Nguyen Linh Tuan

Journal of Machine Engineering

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2023

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Vol. 23, No. 3

130--140

EN

The surface roughness of a part during external cylindrical grinding is directly impacted by cutting force and vibration, which are intermediate parameters. To improve the quality of finished parts, studying and controlling these parameters is essential. In this research, the Taguchi method combined with ANOVA analysis was utilized to analyse the effects of feed rate, cutting depth, and rotational speeds on cutting force and vibration amplitude. The test material used was SKH2 steel, which was heat-treated to a hardness of 60 HRC. The research aimed to investigate the relationship between cutting force, vibration, and surface roughness. The study concludes with an analysis of the influence of cutting force and vibration on the surface roughness of parts during external cylindrical grinding. The results show that as cutting force and vibration increase, the surface roughness of the workpiece in external grinding will also increase, and conversely when cutting force and vibration decrease, the surface roughness will decrease.

11

A review on machinability in the milling processes

Demirpolat Havva, Kuntoğlu Mustafa, Binali Rüstem

Sustainable Production, Instrumentation and Engineering Sciences

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2022

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vol. 1, nr 1

27--36

EN

This review paper focuses on the up-to-date machinability characteristics of milling processes such as cutting forces, surface roughness and tool wear and their impacts on the cutting mechanism. The methodology pur-sued in this paper is to analyze the previous research articles published between 2019–2022 classifying them into the subcategoriesthat usemill-ing operation as manufacturing strategy. As known, milling is one of the most used machining processes in industry and often applied for academic studiesforawide range of materials. Therefore, used sensor systems, main aim and the preferred methodology were summarized in the context of this paper. Seemingly, a great number of machinability papers have been published recently which focuses on the several types of engineering ma-terials and utilized various types of sensor system to improve the surface roughness and tool life. In addition, the investigation showed that optimi-zation approaches have been applied broadly to detect the best machining conditions. Also, it was observed that several modeling approaches such as finite element analysis is a good alternative to analyze the process.

12

Influence of reduced cutting speed values on operator safety and cutting tool life in the processes of manufacturing and regeneration of marine machinery parts

Labuda Wojciech, Charchalis Adam

Journal of KONBiN

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2022

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Vol. 52, iss. 3

1--25

EN

The research used shafts made of X5CrNi18-10 (AISI 304L) stainless steel, which is used, among others in the shipbuilding industry. The turning process was carried out on the CU500MRD universal lathe with the use of cutting inserts with a corner radius of 0.2; 0.4 and 0.8 mm. The measurement of the forces during machining was recorded using a Kistler dynamometer. Surface roughness measurements were made with a Waveline W20 profilometer. The research results are the basis for determining the safe range of application of stainless steel cutting parameters on conventional lathes, with the simultaneous analysis of the quality of the machined surface.

PL

W badaniach wykorzystano wały wykonane ze stali nierdzewnej X5CrNi18-10 (AISI 304L), która znajduje zastosowanie między innymi w przemyśle okrętowym. Proces toczenia zrealizowano na tokarce uniwersalnej CU500MRD z wykorzystaniem płytek skrawających o promieniu naroża 0,2; 0,4 oraz 0,8 mm. Pomiar sił podczas obróbki skrawaniem rejestrowano z wykorzystaniem siłomierza firmy Kistler. Pomiary chropowatości powierzchni wykonano profilometrem Waveline W20. Wyniki badań są podstawą do wyznaczenia bezpiecznego zakresu stosowania parametrów skrawania stali nierdzewnej na tokarkach konwencjonalnych, przy jednoczesnej analizie jakości powierzchni obrobionej.

13

Experimental and Numerical Investigation of Cutting Forces and Temperatures in Milling of Custom 450 Steel

Gökçe Harun

Archives of Metallurgy and Materials

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2022

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Vol. 67, iss. 3

843--853

EN

Stainless steels have a wide usage field, their needs as structural parts are increasing day by day due to their resistance to corrosion and providing sufficient mechanical strength in environments that would cause corrosion. In addition to high mechanical properties of the stainless steels, the low heat transmission coefficients bring problems during machining. In this study, the suitable cutting tool and cutting parameters have been evaluated in terms of cutting forces and the tool temperature, the experimental results and finite element analysis have been compared in the milling of Custom 450 stainless steel which offers especially an excellent working opportunity at high temperature and salinity environment. Milling experiments have been carried out using L16 experimental design for Taguchi method. Four simulations have been made using finite element method with corresponding values in L16 orthogonal array for optimum cutting tool and the results were compared in terms of cutting forces and tool temperature changes.

14

Optimization of micromachining operation for particle reinforced UHMWPE composites

Sofuoğlu Mehmet Alper, Gürgen Selim

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 3

art. no. e138

EN

Unlike metals, polymers are highly affected by the heat generation during the machining of the workpiece, because the thermal conductivity of polymers are considerably lower than metals, and therefore heat is much more effective in the cutting zone. If the appropriate cutting parameters are not selected, the polymers become excessively deformed and the final part has high surface roughness, dimensionally large burr formation, or dimensional deviations. Machining of polymers ultra-high molecular weight polyethylene (UHMWPE) is quite common in industrial applications. In this study, the effect of SiC fillers on the machinability of UHMWPE polymer composite was investigated. First, different samples were produced using different filler sizes (1 μm, 50 μm, and 100 μm) and different filler amounts (1%, 3%, 5%). Micro-milling tests were carried out at a constant feed rate (70 mm/min), constant cutting depth (0.1 mm) and spindle speeds (1200, 2800, and 4400 rpm). Tool overhang lengths were selected as 10, 15, and 20 mm. During the experiments, the surface/burr shapes, cutting temperatures and cutting forces were observed. In general, it is observed that SiC filler reduces cutting forces and cutting temperatures. In the further stage of the study, Taguchi analysis was performed in the light of different SiC filler sizes, filler amounts, rotational speeds, and tool overhang lengths.

15

Path Interval and Its Relevance to Cutting Force in Ball and Filleted End Milling

Sekine Tsutomu

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no. 1

85--94

EN

Computerized milling process is widely used in product manufacturing. Although manufacturing has gradually become highly-automated, the selection of machining conditions still remains an ever-present challenge in the process. To provide some findings contributable for the process planning, this study focuses on ball and filleted end milling. After brief explanations were given to the path interval determinations in both milling processes, the experiments were conducted to verify and characterize each procedure. The results of computational procedures showed good agreement with the experimental ones. Then, material removal rate and cutting force were analytically proposed for effective selection of machining conditions. The following findings were obtained from the demonstrations with discussion. Ball end milling required relatively large cutting force in the first tool path even though the material removal rate was comparatively small. On the contrary, filleted end mill enabled us to maintain a moderate cutting force in the first tool path even if the material removal rate expanded with increasing tool radius.

16

Cutting Forces and 3D Surface Analysis of CFRP Milling

Biruk-Urban Katarzyna, Józwik Jerzy, Bere Paul

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no. 2

206--215

EN

Due to the wide application of Carbon Fiber Reinforced Polymer (CFRP) composites in various industries, more and more attention is paid to machining these materials. One of the most popular way of machining composites is the milling. Milling of composite materials (CM) is a difficult technology due to their anisotropic and heterogeneous structure and the fact that the reinforcing fibers have an intense abrasive effect on the tool edge during machining. The appropriate selection of technological cutting parameters as well as the type and geometry of the tool can significantly affect the value of cutting forces during milling and the quality of the surface after machining. The aim of the paper is to assess the influence of used tools (differing in the number of cutting edges) and various technological parameters of surface milling of CFRP composites on the cutting forces occurring during machining and on the surface quality after machining. Cutting forces were measured during the milling process on a special stand produced by Kistler and the roughness measurements and surface structure were analyzed using the Alicona InfiniteFocusG5 3D optical microscope. On the basis of performed research it was found that 14 edge tool gives lower values of Fx and Fy components of the cutting forces comparing to 2 edge tool, which is especially noticeable at higher cutting speed values vc=160 m/min, where the values of Fx and Fy components decreased by about 43% at fz=0.0030 mm/tooth. This tool gives also lower values of the Sa roughness parameter 1.65 µm.

17

Optymalizacja topologiczna korpusów suportów obrabiarek specjalnych z uwzględnieniem sił skrawania

Śliwka Janusz, Pochopień Tomasz

Stal, Metale & Nowe Technologie

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2021

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nr 5-6

13--19

PL

W artykule przedstawiono metodę optymalizacji topologicznej wybranych korpusów układu suportowego obrabiarki do kolejnictwa. Na przykładzie suwaka głównego przeprowadzono optymalizację topologiczną mającą na celu zredukowanie objętości obszarów biernych. Obliczenia numeryczne uwzględniają działanie sił skrawania, zapewniając dostateczną sztywność węzła.

EN

he article presents a method of topology optimisation of the selected carriage bodies of a railway machine tool. Based on the example of the main slider, topology optimization was performed to reduce the volume of passive areas. Numerical calculations take into account the action of cutting forces, which ensures a sufficient rigidity of the node.

18

Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

Srivastava Arpit, Verma Mukesh Kumar, Niranjan Ramendra Singh, Chandra Abhishek, Patel Praveen Bhai

Production Engineering Archives

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2021

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Vol. 27, Iss. 4

296--305

EN

Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain significant factors and optimal combinations of process parameters.

19

A tool wear condition monitoring approach for end milling based on numerical simulation

Zhu Qinsong, Sun Weifang, Zhou Yuqing, Gao Chen

Eksploatacja i Niezawodność

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2021

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Vol. 23, no. 2

371--380

EN

As an important research area of modern manufacturing, tool condition monitoring (TCM) has attracted much attention, especially artificial intelligence (AI)- based TCM method. However, the training samples obtained in practical experiments have the problem of sample missing and sample insufficiency. A numerical simulation- based TCM method is proposed to solve the above problem. First, a numerical model based on Johnson-Cook model is established, and the model parameters are optimized through orthogonal experiment technology, in which the KL divergence and cosine similarity are used as the evaluation indexes. Second, samples under various tool wear categories are obtained by the optimized numerical model above to provide missing samples not present in the practical experiments and expand sample size. The effectiveness of the proposed method is verified by its application in end milling TCM experiments. The results indicate the classification accuracies of four classifiers (SVM, RF, DT, and GRNN) can be improved significantly by the proposed TCM method.

20

Effect of thermal modification temperature of spruce wood on cutting parameters during circular saw blade cutting

Hlásková Luďka, Kopecký Zdeněk, Novák Vit

Annals of Warsaw University of Life Sciences - SGGW. Forestry and Wood Technology

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2021

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No. 113

30--35

EN

Effect of thermal modification temperature of spruce wood on cutting parameters during circular saw blade cutting. The work examines the effect of temperature on energetical parameters (specific cutting resistance and cutting force) when cutting heat-treated wood of Norway spruce (Picea Abies) by a circular saw. The test samples were heat-treated at 160°C, 180°C, 200°C and 220°C. One sample was not heat treated and was used as a reference sample. In comparison with the theoretical assumptions, the influence of temperature on the cutting force and specific cutting resistance was confirmed. With increasing temperature of modification, the specific cutting resistance and cutting force decreased. The reduction of value of cutting force is related to changes in the chemical structure of the wood components, weight and density loss due to the increasing temperature of modification.

PL

Wpływ temperatury modyfikacji termicznej drewna świerkowego na parametry skrawania podczas cięcia piłą tarczową. W pracy zbadano wpływ temperatury modyfikacji na parametry skrawania (oprór skrawania i siła skrawania) przy cięciu piłą tarczową drewna świerka pospolitego (Picea Abies) poddanego obróbce termicznej. Próbki drewna do badań poddano obróbce w temperaturze 160°C, 180°C, 200°C i 220°C. Jako wariant kontrolny wykorzystano drewno naturalne (nie poddane obróbce termicznej). W ramach badan potwierdzono wpływ temperatury modyfikacji na siłę skrawania i opory skrawania drewna. Wraz ze wzrostem temperatury modyfikacji zmniejszały się wartosci oporu skrawania i siły skrawania. Zmniejszenie wartości siły skrawania związane jest ze zmianami struktury chemicznej składników drewna, ubytkiem masy i gęstości pod wpływem wzrostu temperatury modyfikacji.