Abstract
Understanding the influence of the cutting edge geometry on the development of cutting forces during the milling process is of high importance in order to predict the mechanical loads on the cutting edge as well as the dynamic behavior on the milling tool. The work conducted in this study involves the force development over the entire engagement of a flute in milling, from peak force during the entry phase until the exit phase. The results show a significant difference in the behavior of the cutting process for a highly positive versus a highly negative cutting edge geometry. The negative edge geometry gives rise to larger force magnitudes and very similar developments of the tangential and radial cutting force. The positive cutting edge geometry produces considerably different developments of the tangential and radial cutting force. In case of positive cutting edge geometry, the radial cutting force increases while the uncut chip thickness decreases directly after the entry phase; reaching the peak value after a certain delay. The radial force fluctuation is significantly higher for the positive cutting edge geometry. The understanding of such behavior is important for modelling of the milling process, the design of the cutting edge and the interactive design of digital applications for the selection of the cutting parameters.
Highlights
The design of the cutting edge is commonly defined by its geometrical parameters such as rake angle, edge hone, width and angle of the protection chamfer
Positive cutting edge geometries are often used in milling applications of workpiece materials that have a strong adhesion and/or smearing behavior or for materials prone to show deformation hardening while cutting geometries with negative
Both linear and nonlinear [8] models can be used depending on the curve fitting technique applied. These models include the variation of the chip thickness and the cutting resistance related to the workpiece material but do not include for any dynamic effects related to the chip segmentation or the transient vibrations caused by the entry and exit phases
Summary
The design of the cutting edge is commonly defined by its geometrical parameters such as rake angle, edge hone, width and angle of the protection chamfer. The relationship between the cutting forces and the uncut chip thickness is established from experimental data, i.e. mechanistic force modelling [5,6,7] Both linear and nonlinear [8] models can be used depending on the curve fitting technique applied. These models include the variation of the chip thickness and the cutting resistance related to the workpiece material but do not include for any dynamic effects related to the chip segmentation or the transient vibrations caused by the entry and exit phases. The actual cutting force is affected by the dynamic properties of the machine tool-workpiece system, workpiece material, cutting parameters and cutting edge geometry
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