Prediction of cutting forces in mill turning through process simulation using a five-axis machining center

摘要

Mill turning is a process applied in the milling of a curved surface while the workpiece rotates around its center. Depending on the eccentricity of the tool, when a flat-end mill tool performs a curved trajectory perpendicular to the rotation axis of the tool, its bottom part is engaged in removing material. In order to optimize the process, the cutting force needs to be predicted. Hence, in this work, an approach to simulating the cutting force in mill turning is presented. The case of non-eccentricity of the tool is considered. The undeformed chip geometry is modeling as a function of the tool engagement considering the process kinematics. Experiments were conducted on a five-axis machining center enabling the measurement of the X–Y and Z components of the cutting forces. In order to verify the influence of the bottom part of the tool on the cutting forces, experiments were carried out using three different cutting depths. Numerical cutting simulations and experimental test results are compared to validate the proposed approach.