The assessment of actual cutting forces is vital and essential task for the design and analysis of structural systems. The present study deals with experimental investigation of cutting forces during machining, considering the initial impact during the engagement of cutting tool and work piece. The cutting forces are studied on HSS tool and carbon steel work piece for various cutting parameters. Cutting force assessment directly during machining is a complex task, while the responses because of these forces can be measured using a sensor. The impact cutting force identification on end mill tool is investigated using inverse technique with the aid of frequency response function which measures the structural responses. Experimentally predicted cutting forces are compared with analytically determined cutting forces. Finite element analysis of end mill tool is conceded subjected to the cutting forces to estimate the induced stress, and using induced stress the fatigue life of end mill tool is predicted. The results show that experimental cutting forces predicted are in close agreement with the analytically determined cutting forces. The significance level of the experimental method is 99% having 1% error. Impact effect of cutting forces observed is in the range of 1.093–1.409 than the average cutting force. Cutting tools designed using average cutting force provides false picture of tool life and must be predicted using actual cutting forces.

实际切削力的评估对于结构系统的设计和分析来说是至关重要且必不可少的任务。本研究涉及加工过程中切削力的实验研究，考虑到刀具和工件接合过程中的初始影响。研究了不同切削参数下高速钢刀具和碳钢工件的切削力。在加工过程中直接评估切削力是一项复杂的任务，而由于这些力的响应可以使用传感器来测量。借助测量结构响应的频率响应函数，使用逆向技术研究了立铣刀的冲击切削力识别。将实验预测的切削力与分析确定的切削力进行比较。对立铣刀进行有限元分析，在切削力作用下估算诱导应力，并利用诱导应力对立铣刀的疲劳寿命进行预测。结果表明，预测的实验切削力与分析确定的切削力非常一致。实验方法的显着性水平为 99%，误差为 1%。观察到的切削力的影响比平均切削力在 1.093-1.409 范围内。使用平均切削力设计的切削刀具提供了刀具寿命的错误图像，必须使用实际切削力进行预测。结果表明，预测的实验切削力与分析确定的切削力非常一致。实验方法的显着性水平为 99%，误差为 1%。观察到的切削力的影响比平均切削力在 1.093-1.409 范围内。使用平均切削力设计的切削刀具提供了刀具寿命的错误图像，必须使用实际切削力进行预测。结果表明，预测的实验切削力与分析确定的切削力非常一致。实验方法的显着性水平为 99%，误差为 1%。观察到的切削力的影响比平均切削力在 1.093-1.409 范围内。使用平均切削力设计的切削刀具提供了刀具寿命的错误图像，必须使用实际切削力进行预测。