抄録
The modeling of face milling operations has been traditionally focused on using flat-faced tools with an assumption of a perfectly straight chip formation. However, a curled chip formation is a common phenomenon in practical milling operations, and it has a profound effect on machining performances. A new analytical model that takes into account the chip curling effect in milling operations is presented in this paper. It is shown that chip morphology and machining parameters, such as the chip up-curl radius, the chip thickness, and the tool-chip contact length, simultaneously change with varying undeformed chip thickness during each tooth cycle. The model is validated through the milling tests. A good agreement between theory and experiments has been reached. A comparison of the average resultant force is made among three types of commercially available tool inserts to demonstrate the effect of tool insert chip-groove design on milling performances.
