Smyczek, GregorGregorSmyczekRotshteyn, GrigoryGrigoryRotshteynDegen, FlorianFlorianDegenBergs, ThomasThomasBergs2022-03-062022-03-062018https://publica.fraunhofer.de/handle/publica/26176510.1016/j.procir.2018.09.014Modelling of forces and temperatures for mechanical cutting processes is mainly based on the prevailing local uncut chip geometry. In this context, most researchers use a simplified equation for calculating the uncut chip thickness in milling processes, which neglects the tool movement in feed direction and simplifies the chip thickness. The simplified equation can be easily evaluated, but also adds errors to the calculation results. These errors are typically neglected without knowledge of their exact size. However, the resulting error is dependent on the cutting parameters like cutting speed, tool feed and radial tool engagement and can be very large. In order to quantify the resulting error for different cutting conditions, a novel approach for a more precise calculation of the uncut chip thickness is presented in this paper. Using this new calculation model the uncut chip thickness is determined for industrial relevant cutting parameters and tool dimensions in the first step. The second step includes the direct comparison of the calculated values to the simplified calculation. In this way, the resulting error is illustrated for different cutting situations, mainly focusing on full slot milling and the contact area, where the workpiece surface is generated. As a result, limits for the application of the simplified engagement calculation are presented. In case the limits are exceeded, a more complex and more accurate calculation of the uncut chip thickness has to be used.en658670journal article