Instantaneous shear plane based cutting force model for end milling

The purpose of this paper is to further extend the theoretical understanding of the dynamic end milling process and to derive a computational model to predict the milling force components. A comparative assessment of different cutting force models is performed to demonstrate that the instantaneous shear plane based formulation is physically sound and offers the best agreement with experimental results. The procedure for the calculation of the model parameters used in the cutting force model, based on experimental data, has been presented. The influences of the helix angle on the shear stress, friction angle, and shear angle have also been investigated. The helix angle effect on the cutting force model was experimentally determined and it was shown that the cutting force model is applicable for a wide range of cutter helix angles. The validity of the proposed computational model, based on a discrete representation of the end milling process, has been experimentally verified through a series of cutting tests. The resultant cutting forces were computed as the sum of elemental cutting forces composed of a chip shearing and of a tool–workpiece contact force component.