1577

Prediction of cutting force and temperature

rise in the end-milling operation
P Palanisamy1*, I Rajendran2, S Shanmugasundaram3, and R Saravanan1
1
Department of Mechanical Engineering, Kumaraguru College of Technology, Tamilnadu, India
2
Department of Mechanical Engineering, Bannari Amman Institute of Technology, Tamilnadu, India
3
Government College of Technology, Tamilnadu, India
The manuscript was received on 6 January 2006 and was accepted after revision for publication on 14 June 2006.

DOI: 10.1243/09544054JEM542

Abstract: The cutting force has a significant influence on the dimensional accuracy because
of tool and workpiece deflection in milling. Force modelling in metal cutting is important for
a multitude of purposes, including thermal analysis, tool life estimation, chatter prediction,
and tool condition monitoring. In this paper, the dynamic cutting force model for end
milling is developed to predict the tangential cutting force and the thrust force. The model
prediction is validated with the experimental cutting forces during the machining of AISI
1020 steel using a three-axis milling tool dynamometer. The tool–chip interface temperatures
for different machining conditions are determined using Oxley’s energy partition function
and Rapier’s equation to study the thermal effect on the cutting force. Experiments have
been conducted to validate the predicted temperature using a K-type thermocouple and an
infrared pyrometer. The maximum temperature in the tool increased from 459 to 944
C as
the cutting speed is increased from 20 to 200 m/min when machining at a depth of cut of
2.5 mm. The surface plots have been drawn using MATLAB to indicate the variation in the
cutting temperature in shear and friction zone with the cutting parameters. Knowledge of the
force acting on the cutter and tool–chip interface temperature may help the operator to
select suitable cutting parameters in order to limit the tool–chip interface temperature.

Keywords: milling, cutting force, thermal analysis, finite element analysis

1 INTRODUCTION surface finish). Thus, modelling of the machining

The end-milling operation is most common in the
aerospace industry where large amounts of metal
are removed from solid blocks in order to produce
components with complex profiles. Milling at high
speeds results in high temperature and stress devel-
opment at the chip–tool and workpiece–tool inter-
faces, leading to faster tool wear, distortion of
workpiece surface finish, and increased tooling
cost. It is evident that the cost-effective application
of this technology requires a fundamental under-
standing of the relationships between process vari-
ables (cutting forces and temperatures developed)
and performance measures (tool wear, tool life, and
*Corresponding author: Department of Mechanical Engineer-
ing, Kumaraguru College of Technology, Coimbatore, Tamil-
nadu 641006, India. email: ppalanisamy2003@yahoo.com
process in order to predict process variables is an
essential development to improve tools. There are
several parameters that influence the forces acting
on the cutter. Because of these parameters, the
forces may become unpredictable and result in lar-
ger dimensional variations when products are pro-
duced. Reliable quantitative prediction of the
cutting forces in milling is essential for prediction
of power and torque requirements, tool–chip inter-
face temperature, workpiece surface quality and
geometrical accuracy, and chatter-free cutting para-
meters. The cutting force is directly proportional to
the cross-sectional area of the uncut chip. The pro-
portionality constant is called the specific cutting
force coefficient and depends on the cutter geome-
try, cutting conditions, and workpiece material
properties. In this paper, the dynamic cutting force
model of end milling is presented in section 3. The
developed model is used to predict the cutting force

JEM542
IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1578 P Palanisamy, I Rajendran, S Shanmugasundaram, and R Saravanan
and thrust force in cutting. The predicted cutting
force model is validated with the measured values.
The heat generation during metal-cutting pro-
cesses affects the material’s properties and strongly
influences the cutting forces and tool wear. The tem-
perature of a tool plays an important role in thermal
distortion and the machined part’s dimensional
accuracy, as well as in the tool life in machining.
The tool–chip interface temperature is strongly
affected by the workpiece material, cutting speed,
feed, depth of cut, tool geometry, coolant, and
many other variables. The power consumed in metal
cutting is largely converted into heat near the cutting
edge of the tool, and many of the economic and
technical problems of machining are caused directly
or indirectly by this heating action. The cutting tools
possess high strengths at room temperature, but
they cannot retain useful hardness above the soften-
ing point temperatures. Therefore, a reduction in
tool wear typically requires maintaining the tempe-
rature of the cutting tool below some critical values.
It is therefore important to understand the factors
that influence the generation of heat, the dissipation
of heat, and the temperature distributions in the
tool and workmaterial near the tool edge. Knowledge
of the ways in which the cutting conditions, tool
geometry, and material affect this temperature dis-
tribution is helpful in order to arrive at suitable oper-
ating conditions. Oxley’s energy partition function
and Rapier’s equation are used to study the thermal
effect on cutting force. The maximum temperature
in the tool increased from 459 to 944
C as the cut-
ting speed increased from 20 to 200 m/min when
machining at a depth of cut of 2.5 mm.
2 LITERATURE SURVEY
Taylor [1] was one of the earliest researchers to
investigate the effects of various parameters on the
efficiency of machining. Lacerda and Lima [2] devel-
oped a mathematical model to evaluate forces in the
contact zone between the cutter and workpiece
using an algorithm. They also presented a stability
lobe diagram for an end-milling operation and veri-
fied this experimentally. Huang and Liang [3] pro-
posed a model and finite element method (FEM);
both predict the thrust and tangential cutting forces
and higher tool–chip interface temperature when a
tool with lower cubic boron nitride content is used,
but the model predicts a temperature higher than
that obtained by the FEM. Zhang and Zheng [4] pro-
posed an approach to predict the cutting forces in
peripheral milling of circular corner profiles in
which a varying radial depth of cut is encountered.
A time-domain analytical model of cutting forces
for steady state machining conditions is introduced
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
for each segmented process for the cutting force pre-
diction. Experiments are conducted and the mea-
sured forces are compared with the predictions for
the verification of the proposed method. Kumar
et al. [5] dealt with the modelling of cutting forces
in a face-milling operation performed using self-
propelling inserts. The predicted values of cutting
forces evaluated by the proposed model are in better
agreement with the experimental value than those
predicted using the static force model.
Majumdar et al. [6] developed a model for heat
generations, and the temperature distributions in a
metal-cutting process within primary and secondary
zones and in the rake face owing to friction at the
tool–chip interface were discussed and incorporated
in the FEM. Lazoglu and Altintas [7] presented a
numerically based finite-difference method to pre-
dict tool and chip temperature fields in continuous
machining and time-varying milling processes. Özel
and Altan [8] developed a methodology for simulat-
ing the cutting process in a flat-end-milling opera-
tion and predicting the chip flow, cutting forces,
tool stresses, and temperatures using finite element
analysis. Wangt et al. [9] developed a finite element
model to simulate the heat cycle of the cutting tooth
by a time-varying heat flux. Shet and Deng [10] ana-
lysed the orthogonal metal-cutting process with the
FEM under plane-strain conditions. Finite element
solutions of temperature, stress, strain, and strain
rate fields have been obtained for a range of tool
rake angles and friction coefficients. Results showing
how the tool–chip interfacial friction affects the field
distributions are new and add to the existing know-
ledge base. McFeron and Chao [11] measured the
average tool–chip interface temperature using a
thermocouple technique in peripheral milling.
Liu, Y. J. et al. [12] proposed the particle swarm
optimization (PSO) algorithm for estimating the cut-
ting tool temperature using a non-linear regressive
curve.
The ever-increasing demand on cost reduction
and improving the quality of final products is driving
metal-cutting research into new areas. Modelling
and simulation of cutting processes have the poten-
tial for improving cutting tool designs and selecting
optimum conditions, especially in advanced appli-
cations such as high-speed milling. Nowadays high-
speed machines are employed to increase the output
of industry. Since machining operations are taking
place at increasingly higher speeds and greater
depths of cut, studies in the area of cutting force
and cutting temperature are necessary to improve
the surface finish of the product and tool life. Knowl-
edge of the ways in which the cutting conditions,
tool geometry, and tool material affect the tempera-
ture distribution is essential for the study of cutting
forces and thermal effects on tool life. The user of
JEM542
IMechE 2006
 Prediction of cutting force and temperature rise in the end-milling operation 1579

the machine tool must know how to choose the

cutting parameters to avoid the softening point
temperature of tool material in order to minimize
the tool wear. Therefore, it is important to under-
stand the parameters influencing the cutting force
and temperature. Metal-cutting research should
lead to improved design of cutting tools, machine
tool structures, spindle and feed drives, and optimal
selection of machining parameters based on physi-
cal constraints. The main objective of this study is
to develop a detailed analysis of the effect of the
tool’s thermal property on cutting forces for the
end-milling process.
Fig. 1 Dynamic milling process

3 CUTTING FORCE IN END MILLING Peigne et al. [14] kr ¼ 0.3. Resolving FT and FN
into cutting forces in the x and y directions and
The cutting forces vary with the tool angles, feed, summing for all the teeth engaged will result in
and cutting speed. Knowledge about the forces act- X
z
ing on the cutting tool may help the manufacturer Fx ¼ FTi cos Fi þ FNi sin Fi ð3Þ
of machining tools for the purpose of design and to i1

estimate the power requirement. and

X
z
Fy ¼ FTi sin Fi  FNi cos Fi ð4Þ
3.1 Cutting force model i1

The tooth of a milling cutter can be viewed as a sin- where z is the number of teeth on the cutter.
gle-point tool referring to a rotating coordinate sys- Substitution of equations (1) and (2) into equations
tem, see Li et al. [13]; hence the cutting force in (3) and (4) yields the x and y cutting forces, each
milling can be calculated from a predictive force with three distinct terms: depth of cut b, sine of F
model as presented from cutting conditions, the and cosine of F. Equations (3) and (4) can be
property of the work material, the tool geometry, rewritten as
and the corresponding instantaneous dynamic re-
X
z
generative unreformed chip thickness. Consider the Fx ¼ Ks bf sin Fi cos Fi þ 0:3 sin2 Fi
case of down-milling with a circular tool path assu- i1
med. The cutter is subjected to a tangential cutting 1 Xz

force, and the normal force components as shown ¼ Ks bf sinð2Fi Þ þ 0:3  0:3 cosð2Fi Þ ð5Þ
2 i1
in Fig. 1 may be projected in the x and y coordinate
directions using the rotational position F of the cut- X
z

ting edge. The tooth force during cutting is directly
proportional to the chip thickness.
The tangential cutting force Ft is proportional to
the material-dependent specific energy Ks, the feed
per tooth f, the chip width b, and the rotational posi-
tion F of the cutting edge as given by
Ft ¼ Ks bf sin F ð1Þ
The value of the specific cutting energy Ks is a
function of the feed rate, cutting speed, and
material used for machining and is chosen from the
work of Lacerda and Lima [2],
The normal or radial force FN is assumed to be
proportional to the tangential force Ft according to
FN ¼ kr FT ð2Þ
where kr is the radial cutting force constant
(proportionality constant) that mainly depends on
the cutter geometry. With reference to the work of
Fy ¼ Ks bf sin2 Fi  0:3 sin Fi cos Fi
i1
1 Xz
¼ Ks bf 1  cosð2Fi Þ  0:3ðsin 2Fi Þ ð6Þ
2 i1
where z is the number of teeth on the cutter. The x
and the y force components given in equations (5)
and (6) respectively may be evaluated analytically.
When a tooth enters and leaves the cutting
material, it generates a cyclic cutting force from
zero to maximum and returns to zero for each
tooth in one direction as shown in Figs 2 and 3 for
the x and y directions respectively. The cyclic force
looks like a peak.
3.1.1 Predicted cutting forces
When a tooth enters and leaves the cutting material,
it generates a cyclic cutting force from zero to maxi-
mum and returns to zero for each tooth in one

JEM542
IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1580 P Palanisamy, I Rajendran, S Shanmugasundaram, and R Saravanan

Table 1 Analytical cutting forces (peak) for different

depths of cut

Cutting force (N)

(analytical
values)

Sample Depth of cut (mm) Fx Fy

1 0.5 110 170
2 1 220 340
3 1.5 336 510
4 2 448 680
5 2.5 560 850
Fig. 2 Analytical cutting force variations in the x
direction
Table 2 Specifications of the milling machine, cutter, and
workpiece material

Sample Parameter Value

1 Power 3 kw
2 Diameter of cutter 20 mm
3 Number of teeth 6
4 Material of cutter High-speed steel
5 Composition of T 83 W6 Mo5Cr4 V2
high-speed steel
(grade M 2)
6 Tool geometry Rake angle, 12

Helix angle, 30

L ¼ 130 mm
7 Young’s modulus 200 · 109 N /m2
8 Spindle speed range 0–3000 r/min
9 Feed rate range 16–800 mm/min
10 Workpiece material AISI 1020 steel
Fig. 3 Analytical cutting force variations in the y
11 Specific cutting energy 3400 N/mm2
direction 12 Brinell hardness of 130 HB
workpiece
13 Size of workpiece 150 mm · 50 mm · 10 mm
14 Width of depth of cut 5 mm
direction. Therefore cutting forces are cyclic in
nature. Using equations (5) and (6), the cutting
3.2 Experimental details for measurement
force in the x and y directions are determined
of the cutting force
by varying the rotational angle. The maximum
predicted cutting forces determined using equations A milling operation has been carried out in a Star
(5) and (6) are presented in Table 1. The variation Mill-ATC universal milling machine on AISI 1020
in cutting forces has been drawn in Excel. Figures 2 steel material using high-speed steel grade M2
and 3 show the influence of the axial depth of (T 83W6Mo5Cr6V2) cutter. The specifications of the
cut on the cutting force distribution in the x and y milling machine, cutter, and workpiece material are
directions respectively for an AISI 1020 steel work- given in Table 2. The cutting forces were measured
piece for a constant feed rate of 0.1 mm/tooth. The and monitored using a three-axis milling tool
cutting type is half-immersion down-milling for all dynamometer (IEI model 620-B). The purpose of
cutting tests. The cutting force increases with the experiment is to validate the dynamic cutting
increase in cross-sectional area of chip. In 1 rev of force model. The workpiece is a block of dimensions
the cutter, the area of chip cross-section varies 150 mm · 50 mm · 10 mm. The tests are conducted
from zero at the beginning (at F ¼ 0
) to maximum along the 150 mm edge. The workpiece is rigidly
(at F ¼ 90
). When the axial depth of cut is mounted on a specially designed vice (with sensors
increased, the contact area is increased, and the to measure the forces in the x, y, and z directions)
forces become larger. The predicted cutting force Fx on the machine. These sensors are connected to a
changes from 300 to 560 N whereas Fy changes digital force indicator to displace the force values.
from 6 to 850 N for an axial depth of cut of The cut of 20 mm diameter has been made with a
2.5 mm. The result implies that, when the variation six-tooth cutter mounted in a shrink-fit tool holder.
increases, it is possible for the machining error due The spindle speed and the depth of cut were varied
to tool deflection to increase. The cutting force varia- from 0 to 2000 r/min and from 0.5 to 2.5 mm respec-
tion influences the surface finish of the machined tively. The cutting speed V ¼ 16 m/min (260 r/min)
surface. and the table feed rate f ¼ 160 mm/min were

Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM542
IMechE 2006
 Prediction of cutting force and temperature rise in the end-milling operation 1581

Table 3 Measured cutting forces for different depths due to the increase in frictional force generated
of cut between the cutter flank face and workpiece, as sta-
ted by Toh [15]. The characteristic rises in cutting
Cutting force (N)
(experimental values) forces are due to the increase in the contact area
between the cutter and the workpiece. The Fz com-
Sample Depth of cut (mm) Fx Fy Fz ponent of the cutting forces remains unaffected by
cutter orientation angle and has the lowest value.
1 0.5 123 182 30
2 1 234 364 48 Periodic components of forces produce an overcut
3 1.5 345 528 64 surface since the value is negative. Periodic compo-
4 2 476 695 85 nents of forces produce an undercut surface as the
5 2.5 574 866 116
value is positive. The good agreement between the
analytical and the measured cutting forces clearly
demonstrates the accuracy and the effectiveness of
the model presented.

4 HEAT GENERATIONS IN METAL CUTTING

During metal cutting, a considerable amount of heat

Fig. 4 Comparison of dynamic cutting force components
with various axial depths of cut when employing
down-milling
maintained constant for all tests. The cutting forces
were measured by keeping the feed rate constant
and varying the depth of cut.
is produced owing to the friction between the tool
and workpiece and to the plastic shearing of metal
in the form of chips. This heat reduces the hardness
of the cutting tool, makes it less wear resistant, and
changes its dimensions. Heat also leads to changes
in the dimensions of machined surfaces. These tem-
perature deformations of the tool and workpiece
reduce the machining accuracy. Tool wear increases
as the temperature rises. A study of maximum tem-
perature and temperature distribution in metal cut-
ting is an important part in selecting suitable
cutting parameters.

3.2.1 Measured cutting forces 4.1 Deformation zones in metal cutting

The cutting forces (peak) were measured experimen-
tally with a three-axis milling tool dynamometer
during the machining of the AISI 1020 steel work-
piece for a constant cutting speed of 16 m/min
(260 r/min) by varying the depth of cut for validating
the model developed. The experimentally measured
cutting forces using dynamometer are presented in
Table 3.
3.3 Comparison of predicted and measured
cutting forces
Figure 4 shows a comparison of the predicted cut-
ting forces in X and Y direction for various axial
depths of cut when employing down-milling. Since
the experimentally measured forces are close to the
predicted forces, the model developed is satisfactory.
Fx is the cutting force along the feed of workpiece
and Fy is the cutting force normal to the feed of
workpiece. It is found that the value of Fy is about
34 per cent higher than Fx. Toh [15] has also made
the same observation when employing down-
milling; the magnitude of Fy is higher than that of
Fx. The increase in the magnitude of Fy is mainly
A milling process can be modelled as the simulta-
neous processes of cutting with a number of single-
point cutting tools (the tool having only one major
cutting edge). The major deformations during the
machining process are concentrated in three regions
close to the cutting tool edge. The main regions
where heat is generated during the orthogonal cut-
ting process are shown in Fig. 5. First, heat is gen-
erated in the primary deformation zone (shear
zone) AB owing to plastic work done at the shear
plane. The local heating in this zone results in very
high temperatures, thus softening the material and
allowing greater deformation. Second, heat is gen-
erated in the secondary deformation zone (friction
zone) BC owing to work done in deforming the
chip and in overcoming the sliding friction at the
tool–chip interface zone. Finally, the heat generated
in the tertiary deformation zone (BD), at the
tool–workpiece interface is due to the work done to
overcome friction, which occurs at the rubbing con-
tact between the tool flank face and the newly
machined surface of the workpiece. Heat generation
and temperatures in the primary and secondary

JEM542
IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1582 P Palanisamy, I Rajendran, S Shanmugasundaram, and R Saravanan
Fig. 5 Schematic illustration of orthogonal cutting
zones are highly dependent on the cutting condi-
tions, while heat generation in the territory zone is
strongly influenced by tool flank wear. For a sharp
tool with no wear land, it is assumed that the process
has orthogonal cutting geometry and the chip is
sheared from the blank at an infinitely thin shear
plane (i.e. the primary deformation zone). The chip
slides on the rake face (i.e. the secondary deforma-
tion zone or friction zone) with a constant average
friction coefficient.
4.2 Heat generated in the primary and
secondary deformation zones
The heat generated in metal cutting can be esti-
mated either by calorimetric methods or by using
cutting forces. Using knowledge of the cutting
forces, the rate of energy consumption in metal cut-
ting is given by
Wc ¼ Q ¼ Ft V
where Ft (N) is the tangential cutting force and V
(m/s) is the cutting speed. With reference to the
work of Lazoglu and Altintas [7], the heat Qs
generated per unit depth of cut in the primary zone
and the heat Qf generated per unit depth of cut in
the secondary zone are
thV cosðan Þ
Qs ¼ Fs Vs ¼ J=s
sinðFn Þ cosðFn  an Þ
and
thV sinðbn Þ
Qf ¼ Ff Vc ¼ ¼ F t V x J=s
cosðFn þ bn  an Þ sinðFn  an Þ
respectively where Fs, Ff, V, Vs, Vc, and x are the
shear force in the shear plane, the frictional force
between the tool rake face and the chip contact
zone, the cutting velocity, the cutting velocity
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
component along the shear plane, the cutting
velocity component along the rake face, and the
cutting ratio respectively; t, Fn, an, and bn are the
shear stress in the shear plane, the shear angle,
the normal rake angle, and the normal friction
angle respectively; h is the instantaneous uncut
chip thickness (h equals the feed per revolution for
turning; h ¼ f sin F for end milling, where f is the
feed per tooth and F represents the angular
position of the cutting point). Therefore the total
heat generated during cutting is
Q ¼ Qs þ Qf ð10Þ
where Qs is the heat generation rate in shear
zone and Qf is the heat generation rate in the
friction zone.
Heat is removed from the primary, secondary, and
tertiary zones by the chip, the tool, and the work-
piece. The temperature rise in the cutting tool is
ð7Þ mainly due to the secondary heat source, but the pri-
mary heat source also contributes towards the tem-
perature rise of the cutting tool and indirectly
affects the temperature distribution on the tool
rake face. During the process, part of the heat gener-
ated at the shear plane flows by convection into the
chip and then through the interface zone into the
cutting tool. Therefore, the heat generated at the
shear zone affects the temperature distributions of
ð8Þ
both the tool and the chip sides of the tool–chip
interface, and the temperature rise on the tool rake
face is due to the combined effect of the heat gener-
ated in the primary and secondary zones.
ð9Þ
4.3 Modelling for heat transfer in metal cutting
Determination of the maximum temperature and
temperature distribution along the rake face of the
cutting tool is of particular importance because of
JEM542
IMechE 2006
 Prediction of cutting force and temperature rise in the end-milling operation 1583

Fig. 7 Typical temperature distributions in the cutting

zone
Fig. 6 Elemental heat flow

Equation (16) is the governing equation for heat

its controlling influence on tool life, as well as the
transfer in metal cutting. Figure 7 shows the tem-
quality of the machined part.
perature distribution in the cutting zones in metal
Figure 6 shows a square element ABCD of a chip
cutting. Point X of the chip face which is the fastest
with a width dx and height dy. Point A has coordi-
from the cutting tool is heated while it passes
nates (x, y) and temperature T. The coordinates and
through the primary deformation (shear) zone. Point
temperatures of the element at the four points are
X does not pass through the secondary deformation
shown in Fig. 6, if dT/dx and dT/dy represent
zone. Point Y on the other hand passes through both
the temperature gradients along the x and y axes
the deformation zones. After crossing the defor-
respectively. Then
  mation zone, point Y conducts heat away to point X,
dT 1 dT
Heat transfer along AB ¼ k dy þ rCV T þ dy resulting in a decrease in temperature at point Y and
dy 2 dy
an increase in temperature at point X, that reaches
ð11Þ the maximum temperature at a point off both the
  deformation zones. The total heat generation rate is
d dT
Heat transfer along CD ¼ k Tþ dx dy a sum of conducted and conveyed heats.
dx dx
 
dT 1 dT
þ rCV T þ dx þ dy ð12Þ 4.4 Determination of maximum tool–chip
dx 2 dy
interface temperature
dT
Heat transfer along DA ¼ k dx ð13Þ It is assumed that the change in heat generation at
dx
  the start of cutting is ignored. In the cutting period,
d dT
Heat transfer along BC ¼ k Tþ dy dx ð14Þ constant heat generation takes place on the shear
dy dy
plane and at the tool–chip interface. Only heat con-
where k (W/m k) is the thermal conductivity, C (J/kg duction and heat transfer from the tool faces are


C) is the specific heat capacity, r (kg/m3) is the thought to take place during the cooling period.
density, and V (m/s) is the relative velocity of the The temperature rise Ts in primary deformation
material with respect to the heat source. (shear) zone due to the shearing is determined by
If there is no heating of the element ABCD and the Oxley’s energy partition function [7] according to
heat source is constant in strength, the net heat flow  
1d
into the element is given by Ts ¼ Qs ð17Þ
rCVhb
Heat transfer along AB heat transfer along CD þ
heat transfer along DA heat transfer along BC ¼ 0 where r and C are the mass density and specific heat
Thus capacity of the chip respectively. d represents the
proportion of the shearing flux entering into the
d2 T d2 T rCV dT workpiece and is defined by
þ  ¼0 ð15Þ
dx2 dy 2 k dx
d ¼ 0:5  0:35 log10 ðR tan Fn Þ for 0:004 6 R tanðFn Þ < 10
R is the thermal number which equals rCVb/k and ð18Þ
b is the depth of cut. Therefore, from equation (15)
0:3  0:15 log10 ðR tan Fn Þ for R tan Fn > 10 ð19Þ
2 2
d T d T R dT where the thermal number R ¼ hV/a, the
þ  ¼0 ð16Þ
dx2 dy 2 b dx thermal diffusivity a ¼ k/rC, tan Fn ¼ (b cos an)/

JEM542
IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1584 P Palanisamy, I Rajendran, S Shanmugasundaram, and R Saravanan

Table 4 Analytical cutting forces, thrust forces, and maximum tool–chip interface temperatures (for f ¼ 0.1 mm/tooth)

Maximum
Temperature Temperature temperature
Depth of Cutting Thrust Cutting speed rise in the rise in the at the chip–tool
Sample cut (mm) force (N) force (N) (m/min) primary zone (Ts) secondary zone (Tf) interface (
C)
1 1.0 340 102 20 115 58 198
2 40 136 83 244
3 75 154 113 292
4 100 162 131 319
5 150 174 161 360
6 200 182 185 393
7 1.5 510 153 20 173 87 285
8 40 204 125 353
9 75 231 170 426
10 100 244 197 465
11 150 261 241 527
12 200 274 278 576
13 2.0 680 204 20 230 117 372
14 40 271 166 463
15 75 308 227 560
16 100 325 262 612
17 150 348 321 694
18 200 365 370 760
19 2.5 850 255 20 288 146 459
20 40 339 208 572
21 75 385 284 694
22 100 406 328 759
23 150 435 401 862
24 200 456 463 944

(hb sin an), d is the cut depth, and t is the chip

thickness.
The average temperature rise Tf in the secondary
deformation (friction) zone owing to the friction is
determined by Rapier’s equation [16] according to
Qf
Tf ¼ ð20Þ
rCVwb
The maximum temperature rise Tfm in the sec-
ondary deformation (friction) zone can be
found from
sffiffiffiffi
Tfm R
¼ 1:13 ð21Þ
Tf l0
where l0 ¼ lf/h, lf is the contact length between the
chip and tool, and t is the chip thickness.
Fig. 8 Variations in the shear zone and tool–chip inter-
The maximum temperature at the tool–chip inter-
face temperature with cutting speed
face can be computed from equation [16] (taking the
initial temperature of the workpiece as T0)
Tmax ¼ Ts þ Tfm þ T0 ð22Þ temperatures at the tool–chip interface are much
higher than the temperatures in the shear zone.
The analytically determined maximum tool–chip Most cutting tool materials lose their hardness at
interface temperatures using equation (22) are elevated temperatures, resulting in weakening of
given in Table 4 for different machining conditions the interparticle bond strength and consequent
during the machining of AISI 1020. The variations acceleration of tool wear. With reference to the
in the shear zone and tool–chip interface tem- work by Ezugwu [17], the softening point
peratures with cutting speed for a depth of cut temperatures of commercially available cutting tool
of 2.5 mm and feed of 0.1 mm/tooth are shown in materials are given in Table 5. Hence, the cutting
Fig. 8. It can be seen that the temperatures in the conditions must be selected in such a way that
shear zone and at the tool–chip interface increase the predicted temperature does not exceed the
with increasing cutting speed. It is found that the softening point temperature.

Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM542
IMechE 2006
 Prediction of cutting force and temperature rise in the end-milling operation 1585

Table 5 Softening points of tool materials (after [18]) Table 7 Measured cutting temperatures for a depth of cut
of 1.5 mm and feed rate of 0.1 mm/tooth
Softening point
Sample Tool material temperature (
C) Temperature Temperature
1 High-speed steel 600 Depth Cutting using a K-type using an
2 Cemented carbide (WC) 1100 of cut speed thermocouple infrared
3 Aluminium oxide (Al2O3) 1400 Sample (mm) (m/min) (
C) pyrometer (
C)
4 Cubic boron nitride 1500 1 1.5 20 271 299
5 Diamond 1500 2 1.5 40 339 372
3 1.5 75 409 440
4 1.5 100 448 480
Table 6 Specifications of the K-type thermocouple and
infrared pyrometer

Sample Parameter Specifications

1 Type K-type Infrared
thermocouple pyrometer
2 Model AD 597 TPI 377
3 Power supply D.c. þ 5 V to D.c. þ 9 V
þ 30 V
4 Temperature 200
C to 18
C to
range þ 1250
C þ 1000
C
5 Calibration –4
C –3
C
accuracy

4.5 Experimental validation for predicted

temperature
Experiments have been conducted to validate the
predicted cutting temperatures along the rake face
of the cutting tool in a Star Mill ATC universal
milling machine on AISI 1020 steel using a K-type
(AD 597) thermocouple and a non-contact-type
portable infrared radiation pyrometer (TPI 377).
The specifications of the thermocouple (AD 597)
and the TPI 377 infrared pyrometer are presented
in Table 6. The experimental set-up for temperature
measurement is shown in Fig. 9. The embedded
thermocouple technique uses a thermocouple (K
type), which is placed in a hole of 4 mm drilled in
the workpiece for milling near the cutting edge, as
stated by Longbottom and Lanham [19]. For good
accuracy the depth of the hole needs to be as close
as possible to the surface where the temperature is
to be measured. The device cold junction compen-
sates and amplifies the K-type thermocouple input
to derive an internal signal proportional to tempera-
ture. The internal signal is then compared with
an externally applied set point voltage to yield a
low-impedance switched output voltage. The ther-
mocouple (AD597) can be configured to provide
a temperature output (
C) directly from a K-type
thermocouple signal. For each set of machining
conditions, the output is measured in terms of
temperature.
The infrared pyrometer is fixed near the cutting
edge at a distance of 50 mm. Infrared pyrometers
have been used more than any other method in
reports. They have been used to measure the heat
radiated directly from either the cutting point or
Fig. 9 Experimental set-up for measuring the tool–chip
interface temperature using an infrared pyrometer
and a K-type thermocouple
the workpiece. There are advantages in the use of
infrared sensors; they are of a non-contact nature,
they can respond to rapid changes in temperature,
and they enable the easy measurement of high tem-
peratures without disturbing the heat distribution.
As space around the cutting point is limited, the tar-
get area is small, and the temperature gradients in
the target area are steep, a remote and accurate
method of temperature measurement has advan-
tages. These sensors are reported as being accurate
and reliable, as stated by O’Sullivan and Cotterell
[20]. The infrared pyrometer directly indicates
the temperature when the laser icon is on. The
temperatures measured for each experiment using
the thermocouple and the infrared pyrometer are
presented in Table 7.
4.6 Comparison of predicted and measured
tool–chip interface temperatures
The tool–chip interface temperatures have been
measured to validate the predicted cutting tempera-
ture. Figure 10 shows the comparison of predicted
temperature and measured temperature using a
K-type thermocouple and an infrared pyrometer
with variation in cutting speed when machining at

JEM542
IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1586 P Palanisamy, I Rajendran, S Shanmugasundaram, and R Saravanan
Fig. 10 Comparison of predicted and measured tem-
peratures of the tool–chip interface temperature
when machining at a depth of cut of 1.5 mm
Fig. 11 Variation in the temperature rise in the shear
zone with the depth of cut and feed
a depth of cut of 1.5 mm. The deviation of tempera-
ture measured using the pyrometer is less than that
measured using the K-type thermocouple. This is
because the pyrometer reads directly at the cutting
edge whereas the thermocouple reads the tempera-
ture at some distance from the cutting edge. The var-
iation in temperature with cutting speed is similar to
Strenkowski’s measured temperature versus the
model predictions of Lazoglu and Altintas [7].
4.7 Surface plots
Surface plots have been drawn using MATLAB for
the convenience of selecting the best combinations
of cutting parameter to maintain the cutting tem-
perature. Figures 11 and 12 present the variations
in the temperature rises in the shear and friction
zones respectively for the combination of depth of
cut and feed. A low value of the combination pro-
vides the lowest cutting temperature. It is found
that the variation in temperature rise in the friction
zone is faster than that in the shear zone for
the same cutting condition. This helps suitable
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
Fig. 12 Variation in the temperature rise in the friction
zone with the depth of cut and feed
cutting parameters to be selected to maintain the
temperature within the softening point limit.
5 CONCLUSION
A flexible cutting force model has been developed to
predict the tangential cutting force and thrust force
for an end-milling process. Experiments have been
performed to validate the cutting force model in a
universal milling machine for machining of AISI
1020 steel using a high-speed steel cutter. A compar-
ison of experimental results with the analytical
results has been made. The good agreement between
the analytical and measured cutting forces clearly
demonstrates the accuracy and effectiveness of the
model presented. The cutting forces in general
increase with increase in axial depths of cut, regard-
less of the milling orientation used. Employing a
higher axial depth of cut results in an increased con-
tact area of the workpiece, which increases the cut-
ting force and the mechanical load induced.
Knowledge about the force acting on the cutter
may help the operator to select suitable cutting
parameters.
The cutting forces determined from the model
have been used as input data for determining the
tool–chip interface temperature using Oxley’s energy
partition function and Rapier’s equation. A para-
metric study was carried out to predict quantitatively
the increased temperature level in the tool with
increased cutting speed. The maximum temperature
in the tool increased from 459 to 944
C as the
cutting speed is increased from 20 to 200 m/min
when machining at a depth of cut of 2.5 mm. If
the tool experiences a temperature beyond the
softening point temperature of the tool material,
it rapidly wears. Hence, the cutting conditions
JEM542
IMechE 2006
 Prediction of cutting force and temperature rise in the end-milling operation
must be selected in such a way that the predicted
temperature does not exceed the softening point
temperature.
The cutting force and the temperature at the cut-
ting edge and the finish workpiece surface are used
in designing the cutting edge shape as well as opti-
mizing the feed, speed, and depth of cut to avoid
residual stresses on the finish surface. The surface
plot drawn using MATLAB shows the variations in
temperature rise in the shear and friction zones
with the cutting parameters. It helps suitable cutting
parameters to be selected in order to keep the tem-
perature below the softening point temperature of
the cutting tool.
REFERENCES
1 Taylor, F. W. On the art of cutting metals. Trans. ASME,
1907, 28, 31–350.
2 Lacerda, H. B. and Lima, V. T. Evaluation of cutting
forces and prediction of chatter vibrations in milling.
J. Bras. Soc. Mech. Sci. Engng, 2004, 26(1), 74–81.
3 Huang, Y. and Liang, S. Y. Cutting forces modeling
considering the effect of tool thermal property-
application to CBN hard turning. Int. J. Mach. Tools
Mf., 2003, 43, 307–315.
4 Zhang, L. and Zheng, L. Prediction of cutting forces in
milling of circular corner profiles. Int. J. Mach. Tools
Mf., 2004, 44, 225–235.
5 Kumar, P., Joshi, S., and Kapoor, S. G. Modeling of
cutting forces in a face-milling operation with self-
propelled round insert milling cutter. Int. J. Mach. Tools
Mf., 2005, 20, 1–9.
6 Majumdar, P., Jayaramachandran, R., and Ganesan, S.
Finite element analysis of temperature rise in metal
cutting processes. J. Appl. Thermal Engng, 2005, 25,
2152–2168.
7 Lazoglu, I. and Altintas, Y. Prediction of tool and chip
temperature in continuous and interrupted machining.
Int. J. Mach. Tools Mf., 2002, 42, 1011–1022.
8 Özel, T. and Altan, T. Process simulation using finite
element method prediction of cutting forces, tool stres-
ses and temperatures in high speed flat end milling. Int.
J. Mach. Tools Mf., 2000, 40, 713–738.
9 Wangt, Z. Y., Sahay, C., and Rajurkart, K. P. Tool tem-
peratures and crack development in milling cutters.
Int. J. Mach. Tools Mf., 1996, 36, 129–140.
10 Shet, C. and Deng, X. Finite element analysis of the
orthogonal metal cutting process. J. Mater. Processing
Technol., 2000, 105, 95–109.
11 McFeron, D. E. and Chao, B. T. Transient interface
temperatures in plain peripheral milling. Trans.
ASME, J. Engng Industry, 1958, 80, 321–329.
JEM542
IMechE 2006
1587
12 Liu, Y.-J., Zhang, J.-M., and Wang, S.-Q. Parameter
estimation of cutting tool temperature nonlinear
model using PSO algorithm. J. Zhejiang Univ. Sci.,
2005, 6A(10), 1026–1029.
13 Li, H. Z., Li, X. P., and Chen, Q. A novel chatter stability
criterion for the modeling and simulation of the
dynamic milling process in the time domain. Int. J.
Advd Mfg Technol., 2003, 22, 619–625.
14 Peigne, G., Paris, H., Brissaud, D., and Gouskove, A.
Impact of the cutting dynamics of small radial immer-
sion milling operations on machined surface rough-
ness. Int. J. Mach. Tools Mf., 2004, 44, 1133–1142.
15 Toh, C. K. Static and dynamic cutting force analysis
when high speed rough milling hardened steel. Mater.
Des., 2004, 25, 41–50.
16 Joshi, P. C. Cutting tools, 1996 (A.H. Wheeler & Co. Ltd,
New Delhi).
17 Ezugwu, E. O. High speed machining of aero-engine
alloys. J. Bras. Soc. Mech. Sci. Engng, 2004, 26I, 1–11.
18 Kramer, B. M. On tools materials for high speed mach-
ining. Trans. ASME, J. Engng Industry, 1987, 109, 87–91.
19 Longbottom, J. M. and Lanham, J. D. Cutting tem-
perature measurement while machining – a review.
Int. J. Aircr. Engng Aerospace Technol., 2005, 77(2),
122–130.
20 O’Sullivan, D. and Cotterell, M. Temperature mea-
surement in single point turning. J. Mater. Processing
Technol., 2001, 118, 301–308.
APPENDIX
Notation
b axial depth of cut (mm)
C specific heat capacity (J/kg.C)
f feed rate per tooth (m/tooth)
FN radial force (N)
FT thrust force (N)
Fx, Fy cutting force components in the x and y
directions respectively (N)
h chip thickness (mm)
Ks specific cutting energy (N/mm2)
Kr proportionality constant
Qs heat generation in the shear plane
Qf heat generation in the friction plane
R thermal number
Ts temperature rise in the shear plane (
C)
Tf temperature rise in the friction zone (
C)
z number of teeth on the cutter
a thermal diffusivity
r density of the workpiece material (kg/m3)
f rotational position of cutting edge
Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture