Machining forces prediction for peripheral milling of low-rigidity component with curved geometry

Abstract

This study has developed a model in order to predict machining forces for milling low-rigidity component with curved profile. Differing from conventional models used for straight geometries, the new model takes both the deflection of work piece-cutter system and the continuous change of curvature of machined part into account. In the model, a profile with variable curvature is defined and the feed rate per tooth on the profile is derived subsequently. The cutting force is analyzed simulatively by utilizing modified Newton–Raphson iterative algorithm. The simulative results show that the total radial deflection of workpiece–cutter system is the main factor affecting the change of cutting force. Moreover, the feed rate per tooth and its corresponding cutting force changes according to the curvature of the profile. Finally, experiments were carried out to verify the accuracy of the models.