Cutting Forces Simulation for End Milling

Abstract

The cutting force in end milling is the essential perturbation of the machining system that limits the productivity of the process. Therefore, forecasting the cutting force when assigning the processing mode and the geometry of the allowance layer to be cut is an urgent task that requires an operational tool for its solution. The method of calculating the cutting force is presented, based on a mechanistic approach, when the geometric ratios of the cutter blades’ positions on the sweep determine the thickness of the undeformed chip. The developed algorithm calculates the cutting force by double integration, first by the length of the cutting edge and then by the number of such edges. The algorithm also allows the simulating of the outrun of the mill on the cutting force and its components. The created application program visualizes the simulating process by oscillograms of the cutting force components for both up and down milling. Experimental studies, in general, proved the adequacy of the developed modeling method. The created program is a tool for operational forecasting of the cutting force during the technological preparation of the end milling process in production.