Extension of cutting force formulae for microcutting

During scaling of cutting processes size-effects occur due to not similarly scalable input parameters, e.g. ratio of cutting edge radius to depth of cut. These effects not foreseen by conventional similarity mechanics result in altered behaviour regarding cutting forces, sensitivity for various parameters, chip formation, surface texture and surface layer. This paper identifies effects associated with the transition from macro to microcutting by means of a turning process. Different available models for macroprocesses have been analysed and one has been extended by a term for the cutting edge radius. This results in a significantly better prediction of the acting forces and an enhanced understanding of the process.