Simulation of cutting process in peripheral milling by predictive cutting force model based on minimum cutting energy

The cutting force and the chip flow direction in peripheral milling are predicted by a predictive force model based on the minimum cutting energy. The chip flow model in milling is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The cutting edges are divided into discrete segments and the shear plane cutting models are made on the segments in the chip flow model. In the peripheral milling, the shear plane in the cutting model cannot be completely made when the cutting point is near the workpiece surface. When the shear plane is restricted by the workpiece surface, the cutting energy is estimated taking into account the restricted length of the shear plane. The chip flow angle is determined so as to minimize the cutting energy. Then, the cutting force is predicted in the determined chip flow model corresponding to the workpiece shape. The cutting processes in the traverse and the contour millings are simulated as practical operations and the predicted cutting forces verified in comparison with the measured ones. Because the presented model determines the chip flow angle based on the cutting energy, the change in the chip flow angle can be predicted with the cutting model. (C) 2010 Elsevier Ltd. All rights reserved.