Milling force model prediction considering tool runout with three-teeth alternating disc cutter

Abstract

Disc cutter has a large diameter and more teeth, and obvious tool runout (δi) is produced during disc milling process, so the irregular distribution of cutting force is generated due to uneven distribution of cutting output per tooth (hi*) caused by tool runout. Therefore, the tool runout (δi) must be considered when milling force model of disc milling is established. In the paper, first, milling force model of disc milling is built with a three-teeth alternating disc cutter considering the tool runout (δi). Second, tool runout (δi) is measured by the dial gauge when the revolving speed of disc cutter is 1 r/min, then cutting output per tooth considering tool runout (hi*) is obtained by the formula between cutting output of each tooth (hi) without considering tool runout (δi) and tool runout (δi). Third, the parameters of frictional angle (βn), normal shear angle (ϕn), and shear yield strength (τs) in model coefficients are calibrated by orthogonal cutting experimental. Then, the predictive model of milling force is obtained. Last, the reliability verification experiment of model is conducted. The experiment results show that the model is with high efficiency and precision and the measured force and predictive force is in good agreement in amplitude and trend, which can be used in the study of milling force of disc milling.