Experimental Modelling of Cutting Forces as a Function of Tool Wear in End Milling

Abstract

In end milling with HSS cutters, the cutting force increases as the cutting edge begins to wear. This paper establishes a simple relationship where the cutting force is modeled as a function of the cutting data and tool flank wear, when machining with a particular type of end mill. It was observed that there is an increase in the cutting force components due to an increase in the flank wear of the end milling cutter. These forces rise when the tool begins to wear progressively with time and once the wear reaches a certain value, these forces increase sharply marking the onset of catastrophic tool failure. In this work, two cutting force models are presented. In the first model, a relationship is established between the cutting force and axial (Aa) and radial (Ar) depths of cut and the feed per tooth (Sz) while milling with a sharp cutter. In the second, the effect of tool wear on cutting force is presented.