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Analysis of the cutting forces during machining operations is an important issue. The rough end mill with the serrated profile is broadly used for reduction of cutting forces during milling operation. Since cutting force changes in random behavior during end milling, in this paper we employ fractal theory to analyze the complex structure of cutting force signal. For this purpose, we investigated the influence of variations of cutting depth on variations of fractal structure of cutting forces in wet and dry machining conditions. The results of our analysis showed the variations of fractal structure of cutting forces between different cutting depths, in wet and dry conditions. The employed methodology in this research is not limited to rough end milling and can potentially be applied to other types of machining operations, where the variations of cutting forces is an important issue.

It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force.