Title: Method for rapid characterisation of cutting forces in end milling considering runout

Authors: Stephane Segonds, Yann Landon, Frederic Monies, Pierre Lagarrigue

Addresses: Laboratory of Mechanical Engineering of Toulouse, 3PN, 118 route de Narbonne, 31062 Toulouse cedex 4, France. ' Laboratory of Mechanical Engineering of Toulouse, 3PN, 118 route de Narbonne, 31062 Toulouse cedex 4, France. ' Laboratory of Mechanical Engineering of Toulouse, 3PN, 118 route de Narbonne, 31062 Toulouse cedex 4, France. ' Laboratory of Mechanical Engineering of Toulouse, 3PN, 118 route de Narbonne, 31062 Toulouse cedex 4, France

Abstract: Pocket machining is currently performed by mould and die manufacturers as well as in the aeronautical industry. The good prediction of cutting forces during end milling is so required in order to determine the behaviour of the tool and the workpiece that are the cause of a large number of defects and breakages, or to effectively size the clamping system. Cutting forces depend on a large number of factors, because of cutting parameters and runouts. This study proposes a new method for rapid characterisation of the cutting forces during end milling for a given tool/material couple, from a unique reference test using a single-tooth milling cutter. The variations in forces due to changes in cutting conditions, as in the corners of pockets, as well as axial and radial runouts of the teeth, are integrated in order to effectively predict the instantaneous cutting forces. The comparison between predicted and measured forces is presented. This approach is validated through a milling operation.

Keywords: cutting forces; end milling; pocket machining; runout; cycloid; machinability.

DOI: 10.1504/IJMMM.2006.010658

International Journal of Machining and Machinability of Materials, 2006 Vol.1 No.1, pp.45 - 61

Available online: 14 Aug 2006 *

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