Modeling of cutting forces in end milling based on oblique cutting analysis

Abstract

A force model is presented to predict cutting forces in end milling. The helical end mill geometry model is established containing the cutting velocities and the cutting forces during the cutting process, which considers the pitch angle and the helix angle of each flute. The helical flutes are decomposed into a set of infinitesimal oblique cutting edges. At every oblique cutting element, the geometric angles and the cutting velocities are expressed in the three-dimensional plane and the differential cutting forces are determined by cutting energy in the effective cutting plane. By integrating the differential cutting forces along each cutting edge, which considers the effect of the feed velocity, the milling forces can be predicted. The proposed model has been verified with various cutting tests using regular end mill and variable helix end mill. The predicted and measured cutting forces are compared to illustrate the viability of the proposed cutting force model in end milling.