Theoretical modelling and simulation of cutting forces in face milling with cutter runout

A new approach to theoretical modelling and simulation of cutting forces in face milling is presented. Based on a predictive machining theory, the act ion of a milling cutter is modeled as the simultaneous actions of a number of single-point cutting tools. The milling forces are predicted from the wo rkpiece material properties, cutter parameters, tooth geometry, cutting con ditions and types of milling. The proper ties of the workpiece material are considered as functions of strain, strain-rate and temperature in the cutt ing region. It takes into account the effect of the intermittent contact be tween each milling tooth and the workpiece on the temperature in the cuttin g region. It also takes into account the effect of cutter runout on the und eformed chip thickness. Milling experiments have been conducted to verify t he proposed model. Good agreements between the experimental and simulated r esults are presented. (C) 1999 Elsevier Science Ltd. All rights reserved.