Analysis of cutting process with roughing end mill

A force model based on the minimum cutting energy is applied to simulation of the cutting processes with the roughing end mills. The waveform edges of the roughing end mills are defined as functions of the cutter radius with the cutter height. Because the cutting edges remove the material in the many cutting areas according to the waveform of the edges, the cutting areas on the cutting edges are simulated geometrically with the cutting time and the cutter height. The chip flow model in a cutting area is made with piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The cutting energy is calculated in the orthogonal cutting model. The chip flow direction is determined to minimize the cutting energy consumed in the cutting area. The cutting force loaded on each cutting area can be predicted in the determined chip flow model. Some examples are shown to verify the force model of the roughing end mill.