Abstract
Instantaneous force with static deflection feedback model is applied to predict cutting force and dimensional surface error generation in peripheral milling with irregular tooth pitch end mills. It is demonstrated that the irregular tooth pitch end mill reduces the dimensional surface errors according to the chip regeneration mechanism. Unlike in case of uniform tooth pitch cutters, chip loads on each flute are different in milling with irregular tooth pitch cutters. The excess surface error generated by the flutes which have larger chip loads is removed by the following flutes which have smaller chip load due to the irregular tooth pitch. In order to predict precise cutting force and dimensional surface error for the irregular tooth pitch end mill, the chip regeneration mechanism or the static tool deflection has to be considered to derive the accurate chip loads. Predicted cutting force and dimensional sur face error show good agreement with experimental results. Up to 20% reduction in surface errors is achieved by using the irregular tooth pitch end mills tested.
