DYNAMIC-MODEL FOR END MILLING USING SINGLE-POINT CUTTING THEORY

The dynamics of a milling process can significantly influence the surf ace quality and integrity of the finished part. Accordingly, various r esearchers have investigated the dynamics of milling processes using a hierarchy of models. Tlusty and Smith (1991) provides a review of the se models. In recent years, several other researchers (e.g., Armarego and Deshpande, 1989; Montgomery and Altintas, 1991; Nallakatla and Smi th, 1992) have also continued to enhance various aspects of such dynam ic models. While these dynamic models provide significant insights int o the cutting characteristics of a milling process, their utilization in process design has proven to be elusive. The accuracy of these mode ls, however, depends significantly on the prediction of cutting force characteristics. Under the current state-of-the-art, detailed experime ntations using actual set-up are necessary to make such predictions ac curately. Experimentally obtained constants can vary widely from one m illing situation to another, which in turn, significantly restricts th eir usefulness as predictive tools for process design.