Prediction of cutting forces of Solid end mills with differential helix angles - a numerical approach

Solid end mills with multi-section cutting edges and variable helix angles are available for application. New types of solid end mills for low energy consumption have recently been developed. These so-called Low Power Cutting (LPC)-Tools are characterized by differential helix angles. Compared to solid end mills with variable helix angles, the new differential helix angles change their pitch continuously over the cutting edge length. Due to this fact the cutting conditions are not in a constant state during the revolution of the cutting tool. Existing mathematical approaches for the calculation of cutting forces only consider constant helix angles in milling operations. This paper describes an approach for the prediction of cutting forces for differential helix angles. The developed mathematical model is based on geometrical considerations. Due to a continuously changing pitch over the cutting edge length a numerical approach for the mathematical model is chosen.