Abstract
Analysis tool of milling process is developed to design tool geometry. Dynamic cutting process can be simulated with edge shape function defined as height of cutter. End milling process can be modeled as a pilling up of orthogonal cutting planes containing edge velocity and chip flow direction on divided cutting edges. The model can also consider the effect of slope on cutter trace made by the prior cutting edge. Two types of shear plane model can be realized according to the increasing rate of chip contact length. Chip flow direction can be determined to minimize cutting energy, which is the sum of shear energy on shear plane and friction energy on rake face. Ball end milling process with reduced chip contact length is analyzed to reduce tool vibration with cutting forces. It is shown that analysis software developed is effective for parametric design of cutter shape such in roughing end milling process.
