Cutting force modeling for flat end milling including bottom edge cutting effect

A mechanistic model for cutting force in helical milling of carbon fiber-reinforced polymers

“…The cutting of front edge could be considered in general end milling process [16], but the effect is relatively small. As helical milling process is a combination of drilling and milling, the axial forces are caused by both the side edge and front edge.…”

Phase width analysis of cutting forces considering bottom edge cutting and cutter runout calibration in flat end milling of titanium alloy

“…1 shows the schematic diagram of the flat end milling process, from which it can be seen that both the flank edge and the bottom edge are in contact with the workpiece. According to the work of Dang et al (2010), the total cutting forces are the contributions of the flank and the bottom edge cuttings and can be mathematically expressed as follows:…”

“…What about the contribution of bottom edge on cutting forces and how to identify the size effect in titanium milling still constitute a new challenging topic. Even in the most related work proposed by Dang et al (2010), the cutting force coefficients for the engagement of bottom edge were assumed to be constants that are, in fact, only valid for aluminum alloy. Especially, for the milling process of titanium alloy conducted under small axial depth of cut, the distribution feature of phase widths for non-zero cutting forces is not analyzed in any available works.…”

Mechanistic modeling of five-axis machining with a general end mill considering cutter runout

“…There have been numerous studies on two-dimensional (2D) milling force modeling for flat-end mills [1][2][3], ball-end mills [4][5][6] and general end mills [7][8][9]. Nevertheless, in the field of five-axis milling, most researches focused on the computer-aided manufacturing (CAM) aspect such as tool path planning and collision detection, while few involved the physics of the milling process such as cutting forces.…”