Cutting Force Model in Milling with Cutter Runout

Abstract

Actual milling operations are sometimes accompanied by the cutter runout of the cutting edges, which is induced by the tool clamping error. The cutter runout brings about unequal cutting forces loaded on the cutting edges. Then, different wear rates of the cutting edges reduce the tool life. Therefore, the cutting forces in milling with the cutter runout should be analyzed to perform the milling operation properly. The paper presents an analytical model to evaluate the effect of the cutter runout on the cutting force. In the force model, three-dimensional chip flow in milling is interpreted as a piling up of the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The chip flow direction is determined to minimize the cutting energy. In order to consider the cutter runout, the eccentricity of the center of the tool rotation is included in the coordinate system. Then, the cutting force loaded on each edge is simulated with the rotation radius of edge. The cutting tests were conducted to validate the presented force model. The cutting forces are measured with the cutter runout artificially controlled in the tests. The simulated cutting forces are compared with measured one. The effect of the cutter runout on the cutting force is studied in the simulation.