Abstract
Summary An accurate characterization of cutting forces is essential to the studies of machine tool and cutting dynamics. This paper presents some results of a theoretical and experimental study on cutting forces in face-milling based on a single tooth cutter. The cutting force profile of a multitooth cutter with equal or unequal tooth pitch is obtained by superposition of single tooth profiles. A semi-mechanistic model for predicting cutting force components of a single tooth cutter is derived from metal cutting theories and geometric relations of face-milling process. Three parameters (C, λ, and η) involved in the model reflect the effects of work material properties and cutter geometry (C), undeformed chip thickness (λ), and the ratio of the radial-to-tangential cutting force components (η), respectively. Values of these parameters are determined based on experimental data. A series of experiments was performed with single and multitooth cutters in various cutting conditions. The results show good agreement between the predicted and measured cutting force profiles and magnitudes. The model is simple to use and yields reliable results.
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