Mechanism and force modeling for cross-edges in the flank-end milling process based on the constrained cutting theory

Flank milling is one of the most important processes in modern industries. Traditionally, flank edges are taken as the main part to remove materials. However, cross-edges additionally have a great rule on the machining pro-cess. This paper studies the mechanism of removing materials for cross-edges. First, the mathematical model for cross edges is built. Then, angles for an arbitrary point on a cross-edge embracing the rake, clearance, and inclination angles are deduced. The constrained cutting situation is found in the zone between cross-edges and corresponding their connecting flank-edges. Based on this, the chip-formation mechanism for cross-edges is discussed in deep. Using mechanical principles, cutting forces model due to chips forming is put forward utilizing parameters such as the shear strength, the friction angle, and the shear angle, etc. To combine the effect of environment, tool wear, machine tools error, and so on, an empirical model is obtained from the mechanical one. This paper adopts two methods to verify the validity of the proposed theory. The first one is using FEM software to simulate the milling process to observe the deformation zone in the cutting area using two groups of pa-rameters, the results of the shearing zones for flank-and cross-edges shows that the constrained theory can be used in the cross-edge milling process. Some experiments conducted are the other way to prove the correctness of the cutting forces model. The results also tell us that the model in this paper is valid and of high accuracy.