Establishment and verification of a dynamic cutting force model for metal bandsawing

In this paper, a new model for the cutting force during the bandsawing process is presented by studying its steady and dynamic properties. Considering the sawing and no-sawing states, a single-tooth cutting force model with steady behavior was built. Then, this model was optimized by considering the intermittent feed motion of the bandsaw frame and the instantaneous chip thickness. Finally, a universal dynamic multi-tooth cutting force model with variable tooth pitch was obtained by introducing three periodic characteristics, i.e., single tooth, tooth set, and bandsaw blade transmission. Simulations and experiments verified the proposed model for intermittent feed motion, steady-state characteristics conditions, and cutting force dynamics. The errors in three characteristic frequencies between the simulations and experiments in the cutting force signal were less than 0.059 Hz. Moreover, the dynamic characteristics of the cutting force were primarily affected by the number of sawing teeth that engaged in sawing, intermittent feed motion, and variations in tooth pitch. In addition, the cutting force was approximately proportional to the number of teeth engaged in sawing, and three periodic characteristics of the cutting force were found to be common in the bandsawing process.