Analytical Modelling of Milling Forces for Helical End Milling Based on a Predictive Machining Theory

AbstractMilling forces play an importantrole in the milling process and are generally calculatedbythe mechanistic or numerical methods which are considered time-consuming and impractical forvarious cutting conditions and workpiece-toolpair. Therefore, this paper proposes an analytical method for modelling themilling forcesin helical end milling process based on a predictive machining theory, which regards the workpiece material properties, tool geometry, cutting conditions and types of milling as the input data. In this method,each cutting edge is discretized into a series of infinitesimal elements along the cutter axis and the cutting action of each elementis equivalent to the classical oblique cutting process. The three dimensional cutting force components applied on eachelement are predicted analytically using this predictive oblique cutting modelwith the effect of cutting edge radius. Finally, the proposed analytical model of milling forcesis verified by the publishedresultsandthe simulation values using the software AdvantEdgeFEM