A predictive model for helical end milling forces

Abstract

A predictive model for helical end milling forces is developed using a predictive machining theory, which predicts cutting forces from input data of workpiece material properties, tool geometry and cutting conditions. In the model, each tooth of a helical end milling cutter is discretizised into a number of slices along the cutter axis to account for the helix angle effect on the cutting forces. The cutting action of each of the slices is modeled as an oblique cutting process. For the first slice of each tooth, it is modeled as oblique cutting with end cutting edge effect and tool nose radius effect, whereas the cutting actions of other slices are modeled as oblique cutting without end cutting edge effect and tool nose radius effect. The total cutting forces acting on the cutter is obtained as the sum of the forces at all the cutting slices of all the teeth. Experimental milling tests have been conducted to verify the model which showed good agreements.