An Analytic Mechanistic Cutting Force Model for Milling Operations: A Case Study of Helical Milling Operation

The milling force theory developed (Bayoumi et al., 1994) is applied to conventional helical milling operations. Force relationships for this case were obtained. The process parameters were treated as variables, and a methodology to compute them as a function of rotation angle from the sampled force data was developed. Experiments were carried out to test and/or refine the accuracy of the developed force model. The effect of cutting conditions such as radial and axial engagements and cutting speed on the process parameters was investigated. Some cutting tests were carried out using multiedges cutters at different cutting conditions and different tool and workpiece materials to verify the mechanistic model. The predicted results compared well with the experimental measurements.