This article focuses on the development of a mathematical model of a cutting force that is applicable for coated and uncoated cutting tool inserts and aims to enable more accurate calculation of the cutting force. Two common PVD coatings, AlTiN and TiAlCrN, were used. Firstly, a mathematical model of the cutting force based on the specific cutting force and cutting area is proposed. This mathematical model considers the cutting speed and coating correction factor as well as the real cutting edge geometry, i.e., it includes both the straight and rounded parts of the cutting edge. For this proposed model, material constants for C45 steel, which was machined with uncoated inserts, were obtained. Before determining an equation for a coating correction factor and implementing it into the model, experimental cutting force data for coated and uncoated inserts were compared using a paired t-test. The result was that the difference between them was statistically significant. Their percentage difference was found to be up to 4%. The correction factor equation that was obtained and implemented into the mathematical model was applied to compare the calculated and experimental data of the coated inserts, also using a paired t-test. The result was that the difference between them was insignificant. Moreover, their percentage difference was found to be up to 0.6%.

This paper focuses on mathematical modelling of cutting force with tool wear effect for milling by milling heads. With regard to a small number of experiments with sufficient accuracy, universality, speed and applicability in practice, a mathematical model based on the specific cutting force and cutting area was created. The proposed mathematical model is more refined than other models owing to more accurate calculation of the specific cutting force and cutting area. The calculation of the specific cutting force is more precise due to consideration of the influence of the cutting speed, more accurate calculation of the undeformed chip thickness and implementation of the correction factor of the tool flank wear, which has a significant impact on the cutting force. The calculation of the cutting area is achieved through more accurate calculation of the chip width as well as undeformed chip thickness. The chip width and undeformed chip thickness are refined by consideration of the straight and rounded parts of the cutting edge. For the proposed mathematical model, material constants for the workpiece material made of DIN C45 steel were obtained.

This article focuses on cutting force modelling in the orthogonal turning of two commonly used types of fibre-reinforced plastic materials. Uncoated cutting tool inserts made of sintered carbide and with different rake angles were used for the designed experiments. In addition to the different ra...