An improved cutting force and surface topography prediction model in end milling |
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| Authors: | O.E.E.K. Omar T. El-Wardany E. Ng M.A. Elbestawi |
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| Affiliation: | aDepartment of Mechanical Engineering, McMaster University, ON, Canada L8S 4L7;bMcMaster Manufacturing Research Institute, (MMRI) McMaster University, ON, Canada L8S 4L7;cUnited Technologies Research Center (UTRC), 411 Silver Lane, East Hartford, CT 06108, USA |
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| Abstract: | During the milling operation, the cutting forces will induce vibration on the cutting tool, the workpiece, and the fixtures, which will affect the surface integrity of the final part and consequently the product's quality. In this paper, a generic and improved model is introduced to simultaneously predict the conventional cutting forces along with 3D surface topography during side milling operation. The model incorporates the effects of tool runout, tool deflection, system dynamics, flank face wear, and the tool tilting on the surface roughness. An improved technique to calculate the instantaneous chip thickness is also presented. The model predictions on cutting forces and surface roughness and topography agreed well with experimental results. |
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| Keywords: | Cutting forces Surface roughness Side milling Milling Surface topography Simulation |
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