Generic method to determine coefficients of mechanistic milling force model
by Hossam A. Kishawy; Trevor DesRoches; Ali Hosseini; Tahany El-Wardany; Changsheng Guo
International Journal of Manufacturing Research (IJMR), Vol. 8, No. 1, 2013

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]

Online publication date: Wed, 29-Jan-2014

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