Design and Realization of a Cutting Force Measuring System to Analyze the Chip Removal Process in Rotational Turning

This study focuses on a detailed analysis of the cutting forces in rotational turning, a novel machining process designed to achieve high surface quality and productivity. Unlike traditional longitudinal turning, rotational turning employs a helical cutting-edged tool that performs a circular feeding movement, introducing complex kinematics that complicates the accurate measurement of the cutting forces. To address this, the theoretical background was described for modeling the cutting force removal. The process was experimentally simulated on a CNC milling machine using a custom-designed measurement system. The major cutting force, passive force, and feed force were successfully measured and analyzed under varying feed conditions for both rotational and longitudinal turning. The results demonstrate a significant reduction in the passive force during rotational turning compared to longitudinal turning, which directly contributes to lower elastic deformation in the radial direction of the workpiece. This reduction improves the dimensional accuracy and stability during machining. Additionally, the feed force was observed to be slightly higher in rotational turning, reflecting the influence of the rotational movement of the tool. These findings highlight the advantages of rotational turning for applications requiring precision and surface quality, particularly where radial deformation is a critical concern. This study establishes a reliable methodology for force measurement in rotational turning and provides valuable comparative insights into its performance relative to conventional turning processes.