Predictions of the forces in milling are often needed in order to establish
automation or optimisation of the machining processes. A theoretical model
for forces in milling based on a predictive machining theory and the mecha
nics of milling has been developed and is presented in this paper. In the m
odel, the action of a milling cutter is considered as the simultaneous work
of a number of single-point cutting tools, and milling forces are predicte
d from input data of the workpiece material properties, the cutter paramete
rs and tooth geometry, the cutting condition, and the types of milling. The
workpiece material properties are considered as functions of strain, strai
n rate and temperature, and the calculations for cutting temperature take;
account of the ratio of cutter teeth engagement over milling. Using the mod
el, a Windows-based theoretical milling force simulation system has been de
veloped. The system reads the input data through the menu of its dialogue b
ox for data entry, then conducts milling simulation using the theoretical m
odel and outputs milling force variation against cutter rotation in either
numerical or graphical form, Milling experimental tests were conducted to v
erify the simulation system, the simulation results agreeing well with the
experimental results. (C) 1999 Elsevier Science S.A. All rights reserved.