Cutting force is important in machining because they provide distinctive signature of the mechanics of machining.

It plays a primary role in determining the energy consumed and machining power requirements of process, tool and workpiece deflections. In hard turning, because of the high hardness of the workpiece, it results in higher cutting forces than usual and this reduces the performance of the cutting tool.

by reducing the tool-chip contact, the friction force, F, is reduced, thus cutting forces are reduced. Chip morphology may also change. The tool-chip interface is the major source of friction in cutting, hence a major source of energy dissipation. Also, reducing friction will increase the shear angle and produce thinner chips and requiring less shear energy (see p. 561). These reductions will, in turn, reduce the cutting forces and hence the total energy required to perform the cutting operation. Reducing friction also reduces the amount of heat generated, which results in lower temperatures, with beneficial effects such as extending tool life and maintaining dimensional accuracy. There are several consequences of allowing temperatures to rise to high levels in cutting (see also pp. 571-573), such as: (a) Tool wear will be accelerated due to high temperatures. (b) High temperatures will cause dimensional changes in the workpiece, thus reducing dimensional accuracy. (c) Excessively high temperatures in the cutting zone can induce thermal damage and metallurgical changes to the machined surface. by reducing the tool-chip contact, the friction force, F, is reduced, thus cutting forces are reduced
Self-excited vibrations, or chatter, develop as a result of the dynamic interaction between the structures and the cutting process in machining operations. The wavy surface left by vibrations is removed in the next pass in a dynamic cutting process. The vibrating tool and the wavy surface result in modulated chip thickness, which causes periodically varying cutting forces to excite the machine and workpiece structures. Under certain conditions, the amplitude of the vibrations grows continuously, resulting in instability, i.e. self-excited chatter vibrations.

The vibration occurring in the machine tool is due to the dynamic nature of force acting during the turning operation on the cutting tool.

Phenomenon of effect cutting condition in tool wear:The most apparent phenomenon related to these changes in cutting zone is the occurrence of the (BUE) on the tool. This phenomenon is shown in fig (5-3). The cutting force increase with cutting speed and feed rate, until a speed is reached at which it is a maximum, then with farther increases in speed, the BUE quickly disappear. Then a thin built-up-layer is formed on the face of the tool that varies with further increases in speed, related to these changes are changes in fraction between the chip and tool, which consequently changes the shear plane angle and impacts the components of the cutting force as well. These are best expressed as changes of the chip ratio C, changes of surface roughness and the magnitude, direction of the cutting forces [31].

Chatter vibration, the severe vibration between tool and workpiece under certain cutting conditions, has long been recognized as one of the most significant factors affecting the performance of a machine tool. The occurrence of chatter will result in a decrease of the; metal removal rate and workpiece accuraccy, shortening tool life, and even a reduction of the life of a machine tool. Various attempts, either by active or passive means, have been made over the years to suppress chatter.

The basic cause of chatter is the dynamic interaction of the cutting process and the machine tool structure. During cutting, a force is generated between the tool and workpiece, which acts at an angle to the surface.The magnitude of this cutting force depends largely on the tool-work engagement and depth of cut. The cutting force strains the structure elastically and can cause a relative displacement of the tool and workpiece, which alters the tool-work engagement (undeformed chip thickness). A disturbance in the cutting process (e.g., because of a hard spot in the work material) will cause a deflection of the structure, which may alter the undeformed chip thickness, in turn altering the cutting force. There is a possibility for the initial vibration to be self-sustaining (unstable) and build up, with the machine oscillating in one of its natural modes of vibration. To make the increased capability of modern cutting edges, the cutting-tool materials available, powerful and stable machine tools, holding tools and cutting tools are required. The shape accuracy of the produced parts is determined by the kinematic machine tool behavior and the static, dynamic and thermal stiffness of the machine tool system. The surface quality that can be achieved depends on the geometry of the cutting edge, the machining parameters and the dynamic behavior of the system: machine tool - cutting tool - workpiece. The metal removing capacity that can be achieved without chatter vibrations is clearly defined by the dynamic machine tool behavior. For machining complex shapes of dies and moulds, usually tools with a long overhang are used. Equally the machining of the integral components of aircrafts and cars requires the use of tools with a large length to diameter (L/D) ratio. Also for the machining of boreholes and for the inside machining of cylindrical workpieces long boring bars are required. With increased overhang the tool can become the deciding weak link in the system of machine tool - cutting tool - workpiece. Furthermore, the low static stiffness and material damping characteristics of metallic materials also causes a high dynamic compliance. This can lead to instability of the chip removal process and chatter vibrations.

POOR MACHINING RESULTS ...

... are usually derived from chatter vibrations in machining, with cutting tool damage and unsatisfactory workpiece quality. In order to achieve sufficient process stability, the metal removing rate should be reduced or the cutting tool geometry changed. Material substitution as well as geometric shape optimization leads to increased dynamic stability of boring bars. By the use of passive damping elements, integrated in the boring bars, the dynamic behavior of the tools can be optimized. Generally, machining up to four times the diameter of boring bars does not cause any problems from the vibration point of view, provided that correct conditions apply as regards cutting data and inserts.

There are three different types of damped bars, depending on the length of overhang. Standard bars with a short damping system for machining up to 7 times the bar diameter, standard long bars for machining up to 10 times the bar diameter and cemented carbide reinforced bars (CR bars) for machining up to 14 times the bar diameter.
A vibration is a variable deflection, thus, no defection means no vibration. Vibrations in a cutting tool are triggered and maintained by a dynamic cutting force. Even in a continuous cut, the cutting force will have small rapid changes in both size and direction around a certain average. The keys to eliminate vibrations are the following: Increase static stiffness, reduce cutting forces, and increase dynamic stiffness. Vibrations in the workpiece usually occur with thin-walled parts and non-rigid setups. Unbalance and excessive cutting forces also cause problems. Machine tools should have sufficient stiffness to avoid chatter and vibrations.