In the precision machining scenario of high-speed vertical machining centers, cutting force is the core variable that determines machining accuracy, tool life, and equipment stability. Cutting force modeling provides theoretical support for optimizing machining parameters, designing equipment structures, and improving process reliability by quantifying the interaction forces between cutting tools and workpieces during the cutting process. It has become a key technical support in the manufacturing field.

The core principle of cutting force modeling is based on the physical abstraction and variable coupling analysis of the cutting process. Its essence is to establish a quantitative relationship between force and parameters by analyzing the key influencing factors in cutting motion. The basic assumption is based on metal cutting theory, which simplifies complex three-dimensional cutting into orthogonal or oblique cutting models, focusing on three core variables: tool geometry parameters, workpiece material characteristics, and cutting parameters. The rake angle, rake angle, and edge radius of the cutting tool determine the stress distribution state. The hardness and toughness of the workpiece material directly affect the magnitude of the unit cutting force, while the cutting speed, feed rate, and cutting depth affect the magnitude of the material removal rate by changing the influence.

Modeling methods can be divided into two categories: theoretical analytical methods and experimental modeling methods. The theoretical analysis method is based on material mechanics and plastic deformation theory, and constructs a formula model by deriving the stress-strain relationship during chip formation. It has the advantage of clear physical meaning, but its adaptability to complex working conditions is weak. The experimental modeling method collects cutting force data under different parameter combinations through force sensors, and combines regression analysis or neural network algorithms to fit the model, which is more in line with actual machining scenarios and is currently the mainstream method for high-speed machining scenarios. The fusion application of two methods can achieve a balance between model accuracy and generalization ability.

In practical applications, the value of cutting force modeling is reflected in multidimensional process optimization. At the parameter optimization level, by predicting the changes in force values under different cutting parameters through the model, it is possible to avoid tool breakage caused by excessive cutting forces while ensuring machining efficiency. In a precision mold machining case, the parameters optimized based on modeling increased tool life by more than 30%. At the equipment adaptation level, the modeling results provide a basis for the design of spindle rigidity and optimization of feed system dynamic characteristics in high-speed vertical machining centers, reducing the risk of machining vibration. In automated production, modeling data supports the development of adaptive control systems, enabling real-time adjustment of cutting process parameters and improving the consistency of batch processing.

With the development of high-speed machining technology, cutting force modeling is evolving towards multi field coupling and real-time dynamic direction. In the future, the coupling modeling of multiple factors such as cutting heat and tool wear will further enhance the engineering practicality of the model, providing core technical support for high-speed vertical machining centers to achieve higher precision and efficiency in machining.