Abstract
This paper deals with an accurate cutting force prediction method of end milling in the finishing operation. In order to evaluate the finishing process of end milling, it is necessary to model the workpiece surface precisely. Thus, a cutting process model is proposed. It is based on the actual depth of cut, where the effect of elastic recovery, ploughing force and tool deflection is taken into account. The cutting process in surface generation is investigated from the viewpoint of depth of cut. Three cutting phases, that is, burnishing, rubbing and cutting, are introduced in order to describe the surface generation. Next, a new simulation model is proposed. It is based on the evaluation model of cutting force ratio and actual cutting depth according to three cutting phases. Furthermore, a new procedure of cutting force calculation is proposed in order to consider the effect of error on workpiece surface. The effectiveness of the proposed method is demonstrated by developing the prototype simulation system and making cutting experiments with straight flute end mill, where it is difficult to predict the cutting force by conventional simulation methods. The cutting force measured in the, experiment shows a good qualitative agreement with the predicted one.
