Modelling, simulation and experimental investigation.pdf

Int J Adv Manuf Technol (2012) 63:839–850 DOI 10.1007/s00170-012-3951-4 ORIGINAL ARTICLE Modelling, simulation and experimental investigation of cutting forces during helical milling operations Changyi Liu Gui Wang Matthew S. Dargusch Received: 21 September 2011 /Accepted: 23 January 2012 /Published online: 18 February 2012 # Springer-Verlag London Limited 2012 Abstract The kinematics of helical milling on a three-axis Dm Milling tool diameter (millimetres) machine tool is first analysed. An analytical model dealing F Cutting force (newtons) with time domain cutting forces is proposed in this paper. f va Axial component of helical feed speed The cutting force model is established in order to accurately (millimetres per second) predict the cutting forces and torque during helical milling f vt X– Y plane component of helical feed speed operations as a function of helical feed, spindle velocity, (millimetres per second) axial and radial cutting depth and milling tool geometry. The f za Axial component of helical feed rate per tooth forces both on the side cutting edges and on the end cutting (millimetres) edges along the helical feed path are described by considering f zt X– Y plane component of helical feed rate per the tangential and the axial motion of the tool. The dual tooth (millimetres) periodicity which is caused by the spindle rotation, as well hi, h* Instantaneous undeformed chip width of side as the period of the helical feed of the cutting tool, has cutting edge and end cutting edge (millimetres) been included. Both simulation and experiments have Krc, Ktc, Cutting force coef