Material cutting conditions

Cutting conditions during metalworking depend on the cutting tool, the workpiece material and its surface quality, the feed rate or turn rate, and the cutting speed. The cutting speed is the relative velocity between the surface of the workpiece and the cutting tool. The feed rate is the relative velocity of the cutter along the workpiece. During turning and boring operations the workpiece rotates instead of the cutting tool. The speed of the machining spindle is measured in revolutions per minute and depends on the desired surface speed and the diameter of the workpiece or cutter.

Here are some examples of research on material cutting conditions: The first study investigated cutting operations of annealed and heat treated aluminum alloys bars for aeronautics, using carbide tools, and found that Acoustic Emission (AE) and sensor fusion were effective tools for real time monitoring of material state during the machining process. In the second study researchers used the Taylor model to find optimum cutting speeds, material removal rates and tool life for dry-end milling of titanium alloy Ti–6242S.

The third study investigated the effects of cutting conditions on surface roughness using mathematical regression models during turning operations on aluminum and copper alloys, and gray cast iron, and showed that cutting speeds and feed rates significantly reduced surface roughness, while the working materials had the smallest effect. In the fourth study researchers used mathematical models to investigate the effects of tool materials and cutting conditions on AISI D6 steel during hard turning machining operations and found that the main cutting force, thrust force, and surface roughness increased with increased feed rate, while the cutting temperature and thrust force were affected by the material properties of the tools.

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