PREDICTION OF MILLING FORCE COEFFICIENTS FROM ORTHOGONAL CUTTING DATA

The mechanistic and unified mechanics of cutting approaches to the pre diction of forces in milling operations are briefly described and comp ared The mechanistic approach is shown to depend on milling force coef ficients determined from milling tests for each cutter geometry. By co ntrast the unified mechanics of cutting approach relies on an experime ntally determined orthogonal cutting data base (i.e., shear angle, fri ction coefficient and shear stress), incorporating the tool geometrica l variables, and milling models based on a generic oblique cutting ana lysis. It is shown that the milling force coefficients for all force c omponents and cutter geometrical designs can be predicted from an orth ogonal cutting data base and the generic oblique cutting analysis for use in the predictive mechanistic milling models. This method eliminat es the need for the experimental calibration of each milling cutter ge ometry for the mechanistic approach to force prediction and can be app lied to more complex cutter designs. This method of milling force coef ficient prediction has been experimentally verified when milling Ti6Al 4V titanium alloy for a range of chattel; eccentricity and run-out fre e cutting conditions and cutter geometrical specifications.