AN ANALYTIC MECHANISTIC CUTTING FORCE MODEL FOR MILLING OPERATIONS - A THEORY AND METHODOLOGY

An analytic mechanistic force model has been developed to simulate the cutting forces in milling operations. Steps taken to develop the mode l consisted of cutter surface representation, chip removal kinematics, cutter force definition, and determination of the integration limits from the force equations. The cutter surface is represented by ruled s urfaces that are a function of cutter geometry. Cutter forces are dete rmined by integrating the pressure and friction loads acting on these cutter surfaces. The integration limits that are functions of the rota tion angle are established. Several techniques dealing with the proces s parameters are discussed. The model uses process dependent parameter s representing normal pressure, chip flow friction, and chip flow kine matics. The paper discusses how process data can be used to establish values for the parameters.