Development of a virtual machining system, Part 1: Approximation of the size effect for cutting force prediction

Jeong Hoon Ko, Won Soo Yun, Dong Woo Cho*, Kornel F. Ehmann

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

90 Scopus citations


In this three-part paper, components of a virtual machining system for evaluating and optimizing cutting performance in 21/2-axis NC machining are presented. Part 1 describes a new method of calculating cutting-condition-independent coefficient and its application to the prediction of cutting forces over a wide range of cutting conditions. The prediction of the surface form error and transient cutting simulations, described in Parts 2 and 3, respectively, can be effectively performed based on the cutting force model with the improved size effect model that is presented in Part 1. The relationship between the instantaneous uncut chip thickness and the cutting coefficients is calculated by following the movement of the center position of the cutter, which varies with nominal feed, cutter deflection and runout. The salient feature of the presented method is that it determines the cutting-condition-independent coefficients using experimental data processed for one cutting condition. The direct application of instantaneous cutting coefficient with size effects provides more accurate predictions of the cutting forces. A systematic comparison of the predicted and measured cutting forces over a wide range of cutting conditions confirms the validity of the proposed mechanistic cutting force and size effect models.

Original languageEnglish (US)
Pages (from-to)1595-1605
Number of pages11
JournalInternational Journal of Machine Tools and Manufacture
Issue number15
StatePublished - Dec 2002


  • Cutting force model
  • Cutting-condition-independent coefficient
  • Size effect
  • Virtual machining system

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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