A novel cutting force modelling method for cylindrical end mill

This paper proposes a new and simplified method for the calibration of cutting force coefficients and cutter runout parameters for cylindrical end milling using the instantaneous cutting forces measured instead of average ones. The calibration procedure is derived for a mechanistic cutting force model in which the cutting force coefficients are expressed as the power functions of instantaneous uncut chip thickness (IUCT). The derivations are firstly performed by establishing mathematical relationships between instantaneous cutting forces and IUCT. Then, nonlinear algorithms are proposed to solve the established nonlinear contradiction equations. The typical features of this new calibration method lie in twofold. On the one hand, all derivations are directly based on the tangential, radial and axial cutting force components transformed from the forces which are measured in the workpiece Cartesian coordinate system. This transformation makes the calibration procedure very simple and efficient. On the other hand, only a single cutting test is needed to be performed for calibrating the cutting force coefficients that are valid over a wide range of cutting conditions. The effectiveness of the proposed method in developing cutting force model is demonstrated experimentally with a series of verification cutting tests.