Theoretical modelling and simulation of milling forces

Predictions of the forces in milling are often needed in order to establish automation or optimisation of the machining processes. A theoretical model for forces in milling based on a predictive machining theory and the mechanics of milling has been developed and is presented in this paper. In the model, the action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and milling forces are predicted from input data of the workpiece material properties, the cutter parameters and tooth geometry, the cutting condition, and the types of milling. The workpiece material properties are considered as functions of strain, strain rate and temperature, and the calculations for cutting temperature take account of the ratio of cutter teeth engagement over milling. Using the model, a Windows-based theoretical milling force simulation system has been developed. The system reads the input data through the menu of its dialogue box for data entry, then conducts milling simulation using the theoretical model and outputs milling force variation against cutter rotation in either numerical or graphical form. Milling experimental tests were conducted to verify the simulation system, the simulation results agreeing well with the experimental results.