Abstract
The mechanics and dynamics of helical end milling processes are integrated to a general model. The chip removal geometry is evaluated by considering the true kinematics of the operation and chatter vibrations. The cutting forces are predicted by transforming shear angle, shear stress and friction angle stored in an orthogonal cutting data base to local oblique edge segments along the helical flutes. The general model allows prediction of cutting forces, vibrations, dimensional surface errors and chatter stability lobes for a class of helical end mills. The model is verified experimentally on cylindrical and ball end mills with complex helix geometry.
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