An effective thread milling force prediction model considering instantaneous cutting thickness based on the cylindrical thread milling simplified to side milling process

Abstract

An effective thread milling force prediction model considering instantaneous cutting thickness is presented based on the cylindrical thread milling simplified to the side milling process. Firstly, based on the thread milling process simplified to side milling, an effective calculation model of instantaneous cutting thickness and a milling force model of single-layer cutter teeth are established considering the specific geometric profile of the cutting edge, chip groove angle, and tooth profile angle of the threaded milling cutter. Then, according to the time-domain difference of each layer of cutter teeth, a simplified thread milling force prediction model corresponding to the number of layers can be obtained. Finally, comparing the predicted values of the proposed model with the experimental results of cylindrical thread milling forces, the results show that the average prediction accuracy of Fx, Fy, and Fz are 90.75%, 83.56%, and 78.79%, respectively. The established simplified cylindrical thread milling force prediction model is accurate and reliable.