Mechanistic models for prediction of cutting forces and power consumption considering chip geometry

A novel approach for modeling and simulation of cutting force and power consumption in relation to chip geometry has been proposed in end milling‌ of AISI D2 steel. It is carried out in two stages: experimental work and finite element method based numerical simulation. In the first stage, experiments are conducted on the AISI D2 steel at two levels of spindle rotational speed, axial depth of cuts and four levels of feed per tooth using 10 mm and 8 mm diameter mill cutters. Cutting forces and amplitude of cutter vibration are measured in X and Y directions. Mechanistic models in terms of chip geometry and cutting force coefficients are developed to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation. In the second stage, numerical simulation is carried out to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation and compared with estimated values of cutting forces and power consumption. The maximum error between the two approaches for the cutting forces in X and Y directions and power consumption is estimated as 10.80%, 8.33% and 7.70% respectively. At spindle rotational speed of 2000 rpm, 0.3 mm of axial depth of cut and 50 µm of feed per tooth, the cutting forces and cutting power consumption are found minimum.