FORCE PREDICTION MODELS AND CAD-CAM SOFTWARE FOR HELICAL TOOTH MILLING PROCESSES .1. BASIC APPROACH AND CUTTING ANALYSES

The need for reliable quantitative machining performance information f or efficient and effective use of machining operations is discussed, a s are the recent developments of predictive models and modular softwar e for forces and power in practical operations based on a unified mech anics of cutting approach. The cutting action, comprehensive predictiv e force models and software modules for peripheral milling, end-millin g and slotting operations are developed at three levels of sophisticat ion. The first and basic or 'ideal case' model assumes perfectly rigid cutters with no eccentricity and includes all the important process v ariables, while the second or 'eccentricity' model also includes the i nevitable eccentricity noted in practice. The third and most sophistic ated 'deflection' model incorporates both eccentricity and cutter defl ection in addition to the many process variables. The necessity to ind ividually study each type of milling operation in order to identify, a ssess and verify the appropriate predictive model is highlighted in th is first paper and the findings for each operation are reported in sub sequent parts of this investigation.