Cutting Force Simulation of Corner Radius End Mill Based on Fully Voxel Representation of Cutting Edge and Instantaneous Workpiece Shape

Abstract

A new cutting force simulator, which calculates discretely uncut chip thickness based on fully voxel representation of cutting edge and instantaneous workpiece shape, has been developed to predict cutting force for corner radius end mill. In this cutting force simulator, it is possible to detect the uncut chip thickness between the complex workpiece shape and the special cutting edge shape such as corner radius end mill. Experimental milling tests using a corner radius end mill were conducted for the verification of this cutting force simulation. Predicted milling forces have good agreement with measured milling forces.