Prediction of cutting forces for the milling of plain carbon steel using chamfered main cutting edge tools

A new face milling model for tool geometries with a chamfered main cutting edge has been constructed. Theoretical values for cutting forces were calculated and compared to the experimental results with S45C medium carbon plate as the workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. A comparison of the predicted and measured forces shows good agreement. Special tool holders were designed and manufactured to obtain various tool geometries, including chamfered main cutting edge, radial angle, axial angle and inclination angles. The tips were prepared to the required geometry using a tool grinder.