Theoretical approaches to cutting force determination: a review

Abstract

This article provides a comprehensive review of the main theoretical approaches to determining cutting forces that have been proposed in various scientific studies. Each method is analyzed in terms of its fundamental principles, advantages, limitations, and suitability for application in industrial machining processes. Particular attention is given to the comparison between theoretical calculations and experimental results, which allows for an objective evaluation of the accuracy and reliability of the reviewed models. The paper discusses both classical theories, such as those developed by Merchant and Zorev, and more advanced concepts proposed by researchers like Klocke, Davim, and Astakhov, including energy-based and wave-dependent models. By exploring a wide range of equations and analytical methods, the article highlights how cutting force is influenced by factors such as material properties, cutting speed, depth of cut, and tool geometry. The findings of this review contribute to a better understanding of cutting mechanisms and can be effectively used to improve the prediction of cutting forces, optimize machining parameters, reduce tool wear, and enhance the quality of machined components.