3-DIMENSIONAL CUTTING FORCE ANALYSIS IN END MILLING

The analysis of cutting forces plays an important part in the design o f machine tool systems as well as in the planning, optimization, and c ontrol of machining processes. This paper presents a three-dimensional model of cutting forces in peripheral end milling in terms of materia l properties, cutting parameters, machining configuration, and tool/wo rk geometry. Based on the relationship of the local cutting force and the chip load, the total cutting force model is established via the an gle domain convolution integration of the local forces in the feed, cr oss feed, and axial directions. The integration is taken along the cut ter axis and summarized across the cutting flutes. The convolution int egral leads to a periodic function of cutting forces in the angle doma in and an explicit expression of the dynamic cutting force components in the frequency domain. The closed-form nature of the expressions all ows the prediction and optimization of cutting forces to be performed without the need of numerical iterations. To assess the fidelity of th e analytical model, experimental data from end milling tests are prese nted in the context of three dimensional time waveforms, power spectra , and phase angles, in comparison to the values predicted by the model .