An instantaneous cutting force model for disc mill cutter based on the machining blisk-tunnel of aero-engine

This paper presents an instantaneous cutting force prediction model for a disc mill cutter with indexable inserts. Cutting characteristics, including the normal friction angles, normal shear angles, and shear stress, are decisive factors in determining the instantaneous cutting force coefficients. The cutting characteristics can be determined by several specialized milling experiments, instead of the numerous orthogonal turning experiments that are traditionally used. In this study, the normal friction angles, normal shear angles, and shear stress are determined by a coordinate transformation of the cutting forces and the geometrical parameters of oblique cutting. Then, experiments were used to verify the cutting forces model. The results clearly indicate that shear stress can be described by a constant, nevertheless distributive law of normal shear angle and friction angle fit exponential functions of instantaneous uncut chip thickness. In conclusion, the presented model was found to successfully and accurately forecast the cutting forces of the disc mill cutter with indexable inserts under various machining conditions.