ANALYSIS OF THE MECHANICS OF MACHINING WITH TAPERED END MILLING CUTTERS

The analytical prediction of forces in a tapered mill is of vital inte rest to the accurate machining of complex blade shapes for the aerospa ce industry. Failure of these cutters is more often by chipping and fr acture as opposed to gradual wear. Geometry of the cutters along with duration and length during cutting is analyzed using known parameters. The influence of the geometrical parameters on the spatial distributi on of cutting forces is derived from kinematics and the basic shearing processes. Shear strain is approximately obtained with the use of Sta bler's rule. Stress on the shear plane is found from appropriate shear stress-strain curves. A coefficient of friction on the cutting edge i s used to evaluate the shear as well as normal forces. As a consequenc es, torque experienced by the cutter is evaluated. Finally, verificati on of the analysis is presented through sample calculations and correl ations with experimental data measured with a dynamometer.