Research on a Generalized Simulation Algorithm of Cutting Forces Prediction for Inserted Cutters and Its Implementation

Based on the previous study, this paper presents a generalized simulation algorithm of cutting forces prediction for inserted cutters. The tool nose radius is taken into consideration and the average cutting coefficient model is adopted. The simulation algorithm and related software are developed. Cutting forces for milling cutters with polygon inserts, circular inserts or convex triangular inserts can be predicted. The simulation algorithm has been experimentally verified when milling Al LC4 at various cutting conditions.