Simulation and experimental investigation of the end milling process considering the cutter flexibility

In this paper, a new type of model for the end milling process is presented considering cutter flexibility, which includes not only the static but also the dynamic deflection of the cutter. According to the basic assumption for a linear elastic body, the force acting on the cutter and its deflection in the milling process are both divided into two parts: the static and the dynamic. By considering the regenerative feedback in the practical milling process, the dynamic milling force acting on a unit length of the cutter is derived. Furthermore, a new kind of dynamic deflection model of the cutter is established. Based on this model, a new set of efficient numerical simulation algorithms are presented. In the mean time, the static deflection of the cutter is also formulated. Finally, the simulation and measurement of the milled surface topography for the end milling process show the feasibility of this model