Influence of Process Parameters and Rake Angle on Modeling of Cutting Forces in Wood-Based Materials

The environmental impact of technical systems is becoming increasingly important. Particularly in mechanical engineering, with its high demands on process stability and product quality, environmentally beneficial materials such as wood, with its heterogeneous and anisotropic structure, present challenges. Therefore, understanding the cutting process and the cutting forces is of great importance. This publication builds upon an established cutting force model and presents experiments to determine the specific cutting force (kc0.5) and normal cutting force (kcN0.5) for birch plywood. Furthermore, the influence of the rake angle (Kγ_c and Kγ_cN) and the cutting speed (Kvc and Kvc) on the cutting forces is investigated. These correction factors are integrated into the established cutting model and verified under the assumption of no relevant directional dependence of the cutting forces due to the fibers of the plywood under investigation at the macroscopic level. The correction factors were determined based on the experiments and show a high degree of agreement with experimentally measured values. The correction factors lead to an increase in accuracy of predicting cutting forces during the peripheral milling of birch plywood. The model enables the prediction of cutting force with an average 30% increase in accuracy compared to the reference model. The results thus allow for a more accurate description of the cutting forces, from which important insights can be derived in the future for optimizing the cutting process and the tool, as well as for addressing tool wear and process quality.