Prediction of cutting force distribution and its influence on dimensional accuracy in peripheral milling

Abstract

Cutting force has a significant influence on the dimensional accuracy due to tool and workpiece deflection in peripheral milling. In this paper, the authors present an improved theoretical dynamic cutting force model for peripheral milling, which includes the size effect of undeformed chip thickness, the influence of the effective rake angle and the chip flow angle. The cutting force coefficients in the model were calibrated with the cutting forces measured by Yucesan [18] in tests on a titanium alloy, and the model was proved to be more accurate than the previous models. Based on the model, a few case studies are presented to investigate the cutting force distribution in cutting tests of the titanium alloy. The simulation results indicate that the cutting force distribution in the cut-in process has a significant influence on the dimensional accuracy of the finished part. Suggestions about how to select the cutter and the cutting parameters were given to get an ideal cutting force distribution, so as to reduce the machining error, meanwhile keeping a high productivity.