Title: Generic method to determine coefficients of mechanistic milling force model

Authors: Hossam A. Kishawy; Trevor DesRoches; Ali Hosseini; Tahany El-Wardany; Changsheng Guo

Addresses: Machining Research Laboratory, Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, Oshawa, ON L1H 7K4, Canada ' Machining Research Laboratory, Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, Oshawa, ON L1H 7K4, Canada ' Machining Research Laboratory, Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, Oshawa, ON L1H 7K4, Canada ' Material Science Group, Physical Science Department, United Technologies Research Center, East Hartford, CT 06108, USA ' Material Science Group, Physical Science Department, United Technologies Research Center, East Hartford, CT 06108, USA

Abstract: Precise estimation of cutting coefficients is the fundamental stage of every mechanistic force model to achieve a reliable prediction of cutting forces. This paper presents an efficient method to determine the cutting coefficients for milling operations. The unique feature of the proposed method is that only a single cut is needed to extract the cutting coefficients and calibrate the force model. The single cut enables successive determination of the lumped discrete values of the various cutting coefficients along the cutter axis while the size effect parameters are determined based on the variation of undeformed chip thickness during tool rotation. In order to approve the effectiveness of the proposed model, a serrated tapered ball end mill tool, which has one of the most complicated geometries among milling tools, has been selected to run the tests. The efficiency of this method in determining the cutting coefficients has been confirmed experimentally with a series of verification experiments. [Received 11 May 2011; Revised 29 November 2011; Accepted 1 February 2012]

Keywords: milling; force modelling; cutting coefficients; serrated tapered ball end mill; cutting force; chip thickness.

DOI: 10.1504/IJMR.2013.051839

International Journal of Manufacturing Research, 2013 Vol.8 No.1, pp.43 - 63

Available online: 01 Feb 2013 *

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