Improved analytical chip thickness model for milling

In this paper an analytic expression for chip thickness in milling was formulated while considering the cycloidal motion of the teeth, runout, and uneven teeth spacing. In order to generalize the equation, the cutting parameters associated with milling (linear feed, tool rotational speed, and radius) were combined into a single, non-dimensional parameter. The new parameter allowed abstraction of the milling process and enabled selection of the maximum possible chip thickness in milling. Equations for entry and exit angles of a cut were also developed. The chip thickness values given by the new model were compared to prior models and showed lower error levels.