A milling kinematics model is presented to describe the unique chip geometry for roughing endmills. The reduced edge contact resulting from using roughing endmills is the main mechanism responsible for the decrease in cutting forces and increase in chatter stability. Generally, both lower cutting forces and larger increases in stability with the roughing endmill will result with more flutes, lower feedrates, smaller radial immersions, and larger amplitude of the sinusoidal edge serration. Roughing endmills also decrease the effect of runout on cutting forces. This is an important factor in deep flank milling cuts, where higher peak forces due to runout can cause cutter breakage. These trends are supported by the presented simulation results and experimental cutting tests, and with trends observed in practice at Pratt & Whitney Canada in the flank milling of integrally bladed rotors.
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