Experimental Analysis of Cutting Forces and Finite Element Simulation in Milling Operations

International Journal of Mechanical Engineering
© 2021 by SSRG - IJME Journal
Volume 8 Issue 11
Year of Publication : 2021
Authors : Yahya Işık, Ecenur Öztürk
How to Cite?

Yahya Işık, Ecenur Öztürk, "Experimental Analysis of Cutting Forces and Finite Element Simulation in Milling Operations," International Journal of Mechanical Engineering, vol. 8,  no. 11, pp. 1-7, 2021. Crossref, https://doi.org/10.14445/23488360/IJME-V8I11P101


In this study, the effects of cutting parameters on cutting forces were investigated experimentally in machining. Experiments were carried out by drilling holes with a TiAIN-coated hard carbide cutting tool using a finger milling machine on a CNC vertical machining center. Drilling was performed with AISI 140 as the workpiece material. During the cutting tests, the depth of cut was kept constant at 1 mm and three cutting speeds (100, 120, and 150 m/min) and four different feed rates (0.1, 0.2, 0.3, and 0.4 mm/rev) were used. A Kistler 9333-A force sensor was used to measure the cutting force on the horizontal axis during the machining process. The variation of the cutting force values depending on the cutting parameters was analyzed graphically. The effects of the cutting force values obtained from the experiments on the tools were determined using ANSYS software, and the total deformation and vonMises stresses at the tooltips were compared.


ANSYS, cutting force, cutting speed, depth of cut, feed rate, finite element method


[1] M.A.P. Juarez, et al., Finite Element Simulation and Experimental Analysis of Cutting Forces in Orthogonal Turning in AISI-1045 Steel, ComputationsSystems. 23(1) (2019) 7–20.
[2] I. Nikolaos, I.G. Member, E. Dimitrios, E. Manolakos, Finite Element Analysis of the Cutting Forces in Turning of Femoral Heads from AISI 316L Stainless Steel, Proceedings of the World Congress on EngineeringLondon, U.K. II (2014) 2-4.
[3] H.A, Soliman, A.Y. Shash, T.M. El-Hossainy, M. Abd-Rabou, Cutting forces and crater, wear prediction in orthogonal cutting using two approaches of finite element modeling. Engineering Reports. 2 (2020) 12240.
[4] S.1, Suraidah, M. Ridzuwan1, A. Mebrahitom, I. Asmelash, A. Azhar and F. Mulubrhan, End milling finite element method for cutting force prediction and material removal analysis, IOP Conference Series Materials Science and Engineering (2020) 788.
[5] I.Krajinović, W. Daves, M. Tkadletz, T. Teppernegg, T. Klünsner, et al., Finite element study of the influence of hard coatings on hard metal tool loading during milling, Surface and Coatings Technology. 304 (2016) 134-141.
[6] M.C. Cakır, Y. Isık, Finite element analysis of cutting tools prior to fracture in hard turning operations, Materials and Design. 26 (2005) 105–112,
[7] A. Kurt, Experimental investigation of cutting forces and mechanical stresses during machining and creation of mathematical models.Ph.D. Thesis, GU Graduate School of Natural and Applied Sciences, Ankara, Turkey (2006).
[8] D. Apaydın, Modelling of the cutting forces in the turning of AISI 4340 material using the finite element method.Master’s Thesis, AKU Institute of Science and Technology, Afyonkarahisar, Turkey (2009).
[9] M. Aydın, Analysis of cutting forces and dimensional errors in chip removal with end milling tool by cutting force distribution method, Ph.D. Thesis, KU Graduate School of Natural and Applied Sciences.Kocaeli, Turkey (2014).
[10] A.A.Jadhay, and M.S. Ramgir, Finite Element Simulation of Orthogonal Cutting Process for Steel, International Journal of Engineering Research & Technology (IJERT), 4(4) (2015) 789-793.
[11] H. Gökçe, İ. Çiftçi, H. Gökçe, An investigation into the experimental and finite element analysis of cutting forces in milling: a study on machining of pure molybdenum, Journal of Polytechnic.22(4) (2019) 947-954.
[12] H. Domaç. Investigation of the effects of insert radius and insert geometry on surface roughness and cutting forces in milling. Master's Thesis, GU Graduate School of Natural and Applied Sciences, Ankara, Turkey (2011).
[13] A. Adel, I. Omar, M. El-Shennawy& M. Ayad, Study of wear behavior of as cost TİC/7075 composite, International Journal of Mechanical Engineering (IJME), 4(4) (2015) 45-52
[14] D.Kushawal, R. Ranjan, V.K. Kushawa& M. Tarıq, Evaluation and optimization of cutting parameters for turning of En-8 steel: A Taguchi approach, International Journal of Mechanical Engineering (IJME), 6(4) (2017) 35-44.