A FULLY-FLEXIBLE MODEL OF THE CUTTING FORCE SYSTEM FOR THE DETECTION OFDEPTH-OF-CUT VARIATIONS IN THE END MILLING PROCESS

摘要

Force-based indices used for detection of depth-of-cutrnvariations in end milling have been found to be very sensitivernto cutter geometry, in particular, the helix angle. Poorrnmanufacturing control of such parameters or significant in-cutrncutter deflections could therefore lead to large errors in therndetection of depth-of-cut variations. This paper develops arnmodel for the prediction of the cutting forces in end milling inrnthe presence of cutter deflection. This new model includes anrnelliptical discretization schema of the cutter under deflectionrnand a model of deflection-dependent effective cutterrngeometries. The flexible cutting forces are obtained by solvingrnfor the chip load and effective cutter geometries that balancernthe cutting forces and deflections. The model-predicted cuttingrnforces and the associated force shape characteristic indices usedrnin the depth-of-cut variation estimation are compared to bothrnmeasured and other model-predicted values.