Prediction of Cutting Force in End Milling : Simple Prediction Method by Superposition

This paper proposes a simple and accurate method for the prediction of the cutting force in end milling. The cutting force in end milling of a thick plate can be predicted by adding the cutting forces in end milling of a thin plate. The following were obtained from the comparison of the predicted cutting force with the experimental results. (1) The error of the predicted cutting force is reduced with a increased helix angle of the cutting edge of the end mill and a decreased radial depth of cut. (2) The error of the predicted cutting force of a 1-tooth end mill is less than about 200N under cutting conditions of 2～10mm radial and 2～20mm axial depth of cut and 10°～50° helix angle. The maximum error occurs at the helix angle of 10°, but the ratio of the error to the maximum cutting force is less than 10%. (4) The cutting force of a 4-tooth end mill can be predicted by superposition of that of a 1-tooth end mill. The maximum error and ratio are also less than 200N and 10% respectively