Fast evaluation of cutting forces in milling, applying no approximate models

A new method for fast evaluation of cutting forces in milling is introduced and tested experimentally. Unlike all existing procedures, which include the use of cutting models and approximate assumptions, in this method, the elementary functions of the cutting force are obtained from measured values only.The basic force functions for the whole feed range are acquired from one experiment using a single-tooth full-diameter (slot) milling, applying a specially developed procedure. The milling experiment is conducted under low-impact conditions, enabling accurate measurement and convenient signal processing. The basic force functions are then integrated and superimposed, using known procedures, to combine the total force in any multitooth milling combination. In this work the method is explained and tested experimentally.The suggested method enables a reliable evaluation of the cutting forces, while demanding minimal experimental work, the method applies to cutters having complicated edge geometry, and to high speed milling.Nomenclature a radial depth of cut 0<a<D - feed per tooth ratio 0<1 - d axial depth of cut - D cutter diameter - a/D radial depth ratio - cutter rotation angle - cutter rotation angle 6] - F _x,y,z() instantaneous edge cutting forces in fixture coordinates - F _t,r,z() instantaneous edge cutting forces in tool coordinates - F _x,y,z ^* F_t,r,z tool cutting force components on a multitooth cutter - h instantaneous chip thickness 6] - h* equivalent edge coefficient 6] - r ₁,r ₂ tangential radial ratio coefficient 6] - K _T tangential specific cutting force 4] - K _R radial specific cutting force 4] - N number of teeth - R _r resolution reduction factor - t instantaneous chip thickness - S ₁,S feed per tooth