Abstract
The geometrical analysis of a new three-dimensional force model of end milling is presented. The analysis includes description of the relative relationships among undeformed chip thickness, rake angle, cutting velocity, shear plane area and chip flow angle during peripheral and face milling processes. The shear plane area of the shear deformation zone and the effective frictional area on the tool face are calculated and the shear energy per unit time and frictional energy per unit time are formulated. The three-dimensional cutting forces in the tool axis system are then obtained. In the developed model, the depth of cut, helix angle, tool rotational angle, and indentation action of the tool tip are taken into account by individual transformation matrices. The three-dimensional cutting forces in a Cartesian system can be predicted via matrix transformation. Experiments conducted to verify the developed model showed that the predicted cutting forces agreed well with the experimental data both in trends and values.
Similar content being viewed by others
References
Kline WA, DeVor RE, Lindberg JR (1982) Prediction of cutting forces in end milling with application to cornering cuts. Int J Mach Tools Design Res 22(1):7–22
Abrari F, Elbestawi MA (1997) Closed form formulation of cutting forces for ball and flat end mills. Int J Mach Tools Manufact 37(1):17–27
Zheng Li, Steven Y Liang, Shreyes N Melkote (1998) Angle domain analytical model for end milling forces. J Manu Sci Eng 120(2):252–258
Li HZ, Zhang WB, Li XP (2001) Modeling cutting force in helical end milling using a predictive machining theory. Int J Mech Sci 43(8):1711–1730
Engin S, Altintas Y (2001) Mechanics and dynamics of general milling cutters. Part E: helical end mills. Int J Mach Tools Manufact 41:2195–2212
Junz Wang J-J, Yang CS (2003) Angle and frequency domain force models for a roughing end mill with a sinusoidal edge profile. Int J Mach Tools Manufact 43:1509–1520
Kivanc EB, Budak E (2004) Structural modeling of end mills for form error and stability analysis. Int J Mach Tools Manufact 44:1151–1161
Usui E, Hirota A, Masuko M (1978) Analytical prediction of three dimensional cutting process. Part 1: basic cutiing model and energy approach. Trans ASME J Eng Industry 100:222–228
Usui E, Hirota A (1978) Analytical prediction of three dimensional cutting process. Part 2 chip formation and cutting force with conventional single-point tool. Trans ASME J Eng Industry 100:229–235
Ueda N, Matuso T (1986) An investigation of some shear angle theories. CIRP Ann 35:27–30
Nakayama K, Arai M (1976) On the storage of data on metal cutting forces. CIRP Ann 25:13–18
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Tsai, CL. Analysis and prediction of cutting forces in end milling by means of a geometrical model. Int J Adv Manuf Technol 31, 888–896 (2007). https://doi.org/10.1007/s00170-005-0275-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-005-0275-7