AN ANALYTIC MECHANISTIC CUTTING FORCE MODEL FOR MILLING OPERATIONS - A CASE-STUDY OF HELICAL MILLING OPERATIONS

The milling force theory developed (Bayoumi et al., 1994) is applied t o conventional helical milling operations. Force relationships for thi s case were obtained. The process parameters were treated as variables , and a methodology to compute them as a function of rotation angle fr om the sampled force data was developed. Experiments were carried out to test and/or refine the accuracy of the developed force model. The e ffect of cutting conditions such as radial and axial engagements and c utting speed on the process parameters was investigated Some cutting t ests were carried out using multiedges cutters at different cutting co nditions and different tool and workpiece materials to verify the mech anistic model. The predicted results compared well with the experiment al measurements.