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Analytical modelling of milling forces for helical end milling based on a predictive machining theory

: Fu, Z.T.; Yang, W.Y.; Wang, X.L.; Leopold, J.

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Procedia CIRP 31 (2015), pp.258-263
ISSN: 2212-8271
Conference on Modelling of Machining Operations (CMMO) <15, 2015, Karlsruhe>
Journal Article, Conference Paper, Electronic Publication
Fraunhofer IWU ()

Milling forces play an important role in the milling process and are generally calculated by the mechanistic or numerical methods which are considered time-consuming and impractical for various cutting conditions and workpiece-tool pair. Therefore, this paper proposes an analytical method for modelling the milling forces in helical end milling process based on a predictive machining theory, which regards the workpiece material properties, tool geometry, cutting conditions and types of milling as the input data. In this method, each cutting edge is discretized into a series of infinitesimal elements along the cutter axis and the cutting action of each element is equivalent to the classical oblique cutting process. The three dimensional cutting force components applied on each element are predicted analytically using this predictive oblique cutting model with the effect of cutting edge radius. Finally, the proposed analytical model of milling forces is verified by the published results and the simulation values using the software AdvantEdge FEM.