Abstract
This article presents a mathematical model of helical end-milling forces through experimental identification of the cutting coefficients and analyzes the changes of corner-milling forces under different conditions. In allusion to the corner-milling process, the relationship between working parameters and the corner coordinates is investigated by way of combination of tool tracing and cutting geometrodynamics. The milling parameters are optimized by changing the coordinates of tool center and working parameters without altering cutting forces. By applying the optimized parameters to milling practice, a comparison is made to show the improved product quality. Based on these optimized parameters, a finite element method (FEM) program is used to compute deformation values of a workpiece's corner, which evidences few effects that optimized parameters can exert on the corner deformation.
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