Milling process study, assuming estimation of cutting force

The paper presents results of research of a milling process, which include experimental studies associated with determination of cutting forces. Cutting depth is a parameter that was varied in the course of the measurements. Analytical models were constructed for cutting force prediction on the basis of experimental data obtained for tool geometry, cross-section of removed material layer and cutting regimes. A tool with two inserts was used for milling experiments: during cutting process one insert was removing the material layer, while the other was idle. Analytical models for cutting force evaluation were developed for a single cutting insert. The accuracy of the models was improved by taking into account the specific cutting pressure that was determined experimentally. Chip cross-section varies in the course of the milling process therefore the models allow to estimate cutting forces by adopting the assumption of average chip thickness. Finally, a finite element model was built taking into account the magnitude of material cross-section that is removed during milling operation.