The prediction of cutting forces in end milling with application to cornering cuts

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Abstract

This paper presents the development, verification, and implementation of a mechanistic model for the force system in end milling. This model is based on chip load, cut geometry, and the relationship between cutting forces and chip load. A model building procedure based on experimentally obtained average forces is presented and both instantaneous and average force system characteristics are described as a function of cut geometry and feed rate. A computer program developed to implement the mechanistic model provides tabular and graphical outputs which show force distributions as functions of the axial depth of cut and rotation of the cutter. Force characteristics during concerning cuts are predicted by the model and verified via a set of cornering cut experiments typical of aerospace machining operations. Force characteristics in cornering are examined as a function of axial depth of cut and feedrate.

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