On cutting forces in peripheral milling of curved surfaces

Abstract

This paper presents the development of an analytical model of cutting forces in peripheral milling of curved surfaces. The effect of the workpiece curvature is taken into account in the model construction. Based on the relationship of differential cutting forces and chip load, the total cutting forces are formulated by integration of the differential cutting forces along the cutting flutes in the feed and cross-feed directions. This formulation leads to an explicit expression for the force waveforms as algebraic functions of cutter variables, process parameters, machining configuration and workpiece geometry. Experiments are performed over a wide range of conditions to verify the model and meanwhile the effects of the process parameters on the cutting forces are revealed. The presented model facilitates force estimation and provides a basis for the analysis, prediction and improvement of surface accuracy in peripheral milling of curved surfaces.