An improved dynamic cutting force model for end-milling process

An improved dynamic cutting force model for end-milling operation is developed based on a developed algorithm for calculation of instantaneous shear plane area and taking into account into the cutter geometry, influence of vibration, cutting speed variation, and friction between cutter and chips. To determine the instantaneous cutting force, the cutting edges of end-milling cutter are discretized into limited number of elements, and the forces exerted by each element regarded as oblique cutting are calculated. By summing up the cutting forces generated by elemental edges, the instantaneous cutting forces of end milling can be determined. A theoretical–empirical method to determine the parameters needed for cutting force calculation was proposed. Cutting experiments on aluminum were performed to compare with the proposed model.