Abstract
The accurate prediction of cutting forces is important in controlling the tool deflection and the machining accuracy. In this paper, the authors present an improved theoretical dynamic cutting-force model for peripheral milling with helical end-mills. The theoretical model is based on the oblique cutting principle and includes the size effect of undeformed chip thickness and the influence of the effective rake angle. A set of closed-form analytical expressions is presented. Using the cutting forces measured by Yucesan [1] in tests on a titanium alloy, the cutting-force coefficients are estimated and the cutting-force model verified by simulation. The simulation results indicate that the improved dynamic cutting-force model does predict the cutting forces in peripheral milling accurately. Simulation results for a number of particular examples are presented.
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