New equations for highly precise prediction of the cutting force in thrust force-free cutting

When processing microshafts by turning, the thrust force causes flexural deformation of the workpiece and adversely affects machining accuracy. A method for minimizing the thrust force was proposed. The aim of this study is to predict the thrust force-free cutting conditions theoretically. When the feed rate is comparable to the cutting edge radius, the cutting edge radius has a marked effect on the cutting mechanism and the minimum uncut chip thickness (MUCT) is not negligible. By considering the MUCT, the accuracy of the cutting force prediction was improved.