Milling force modeling for disc milling cutter of indexable three-sided inserts considering tool runout

Cutting force is essential for studying cutting mechanism and improving cutting process. In order to predict cutting force, the cutting force was measured by experiments; cutter runout was measured by dial indicator; the actual undeformed cutting thickness was obtained in presence of cutter runout. Then a mechanical cutting force model was established. Three kinds of cutting force coefficients, linear, exponential, and polynomial coefficients, are solved and compared. The results show that the exponential model has the highest generality and accuracy. The validation experiment illustrates deviation rates between the predicted values and measured values are mostly <30%, and the deviation rates of the middle inserts are greater than that of the left and right inserts. The mechanical model in this paper can predict the cutting force quickly, which is helpful to select the reasonable cutting parameters and lays a foundation for the research of multi tooth cutting force.