Analytical model of milling forces prediction in five-axis milling process

Abstract

In the process of the five-axis milling process, due to the changing of the cutter-workpiece engagement area and instantaneous uncut chip thickness, five-axis milling forces prediction is difficult compared with three-axis forces prediction. This study proposed a new analytical method to predict milling force in five-axis milling. Compared with the mechanistic calibration method and experiment method, this method predicts the cutting force accurately, does not need experiments, and only needs to know the input parameters, such as tool parameters, workpiece parameters, and cutting conditions. The effect of lead angle and tilt angle is analyzed by theoretical simulation. The correctness of the prediction model is verified by experiments under different conditions.