The International Journal of R d v a n c e d m a n u f a c t u r i n g T e c h n o l o g u A General i sed Model of Milling Forces Li Zheng, Yawei Li and Steven Y. Liang George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, USA This paper presents the development of a generalised cutting force model f or both end-milling and face-milling operations. The model specifies the interaction between workpiece and multiple cutter ,flutes by the convolution of cutting-edge geometry function with a train of impulses having the period equivalent to tooth spacing. Meanwhile, the effect of radial and axial depths of cut are represented by the modulation of the cutting-edge geometry function with a rectangular window function. This formulation leads to the development of an expression of end~face-milling forces in explicit terms of material properties, tool geometry, cutting parameters and process configuration. The explicimess of the resulting model provides a unique alternative to other studies in the literature commonly based on numerical integrations. The closed-form nature of the cutting force expression can facilitate the plan- ning, optimisation, monitoring, and control of milling oper- ations wiIh complicated tool-work interactions. Experiments were performed over various cutting conditions and results are presented, in verification of the model fidelity, in both the angle and frequency domains. Keywor ds: Forces; Generalised; Milling; Model 1. I n t r o d u c t i o n Cutting force is an important physical variable that embodies relevant process information of machining. Such information can be used to understand process attributes related to machin- ability, cutter wear/fracture, chatter, part dimensional accuracy and surface finish [1-3]. The modelling of milling forces with complicated tool and workpiece geometry generally involves the determination of local cutting forces at one cutting point and the integration of the local cutting forces along cutting edges. Koenigsberger and Sabberwal [4] treated the local tangential force as the product of a specific cutting pressure and instantaneous chip load. Tlusty and MacNeil [1] considered the radial local force to be proportional to the tangential local Correspondence and offprint requests to: Dr S. Y. Liang, The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405, USA. force. These basic relationships have been widely used by other researchers [2,3,5-8] to develop force models incorporat- ing such considerations as cutter runout, spindle tilt, and system deflections. In the integration of local cutting forces, both numerical integration and analytical methods have been documented. While numerical integration [2,3,6] is a general, convenient and effective cutting-force estimation method, analytical inte- gration provides an explicit cutting-force expression to enable process optimisation, machine-tool design and on-line control. Bayoumi et al. [9,10] achieved a closed-form expression for cutting forces for helical milling operations in the time domain by mathematical integration. The change of cutting engagement calls for the use of different integration limits in various cutting segments, therefore different formulae for cutting forces were presented for various cutting angles. Yellowley [11] gave analytical expressions of torque and forces via the integration of tile local cutting force of straight cutting edge represented by a Fourier series. The model was developed for either single helical flute or multiple straight flutes, while the general case of multiple helical cutting edges was not addressed. Liang and Wang [12] developed a convolution integration method by which an explicit expression for dynamic cutting-force compo- nents could be obtained. The resulting model was given in the frequency domain and it is limited to the end-milling operation. In this paper, a generalised model is developed to provide analytical, explicit, and algebraic expressions for cutting forces applicable to both end-milling and face-milling processes involving multiple helical flutes. It involves the representation of a generalised cutting-edge function, integration of local cutting forces, formulation of dynamic cutting-force compo- nents, and reconstruction of cutting-force waveforms. The method used here avoids the search for integration limits of different cutting engagement segments, and generates a single expression for cutting forces that covers the entire cutter rotation range. The dynamic cutting forces in the model are explicitly expressed in terms of material properties, tool geometry, cutting parameters, and process configuration. The explicit expression provides an advantage over the commonly used method of numerical integration for machine-tool vibration analysis, process optimisation, machine-tool design, and on- line diagnostics. The development of this model is based on a generalised cutting-edge function rather than for any specific Z(H) x _ R 0 _ Fig. 1. Cuning edge representation in both cylindrical and cutting-force coordinate systems. cut t er geomet r y and pr ocess configuration. Ther ef or e, the model is generi c and can be used to devel op a cut t i ng f or ce model f or any mi l l i ng oper at i on wi t h known cut t er geomet r y. The cut t i ng- edge f unct i ons and cut t i ng- f or ce model s f or bot h f ace mi l l i ng and end mi l l i ng are pr esent ed as degener at ed cases of A Generalised Model of Milling Forces 161 the gener al i sed cut t i ng f or ce model . Exper i ment s are per f or med and resul t s pr esent ed to ver i f y t he analytical model s. 2. Model Devel opment 2.1 Cutting-Edge Representation A cyl i ndri cal coor di nat e syst em is used in this st udy to rep- r esent a cut t i ng edge, as shown in Fig. 1. Suppose the H di rect i on is in t he di rect i on of the angul ar vel oci t y o f t he spindle, t he gener al i sed cut t i ng engagement in t er ms o f hei ght H and radi us R o f cut t i ng poi nt s in cont i nuous and mul t i t oot h cut t i ng can be denot ed as: g = h([3), Tth([3), R = r([3)*Tth([3) ~ ( 2 " r r ( i - 1 ) ) wher e Tth([3) = ~ 8 [3 N (1) i=I Not e t hat t he t oot h sequence funct i on, 77h([3), is a train of unit i mpul ses havi ng the per i od of the t oot h spacing. Si nce a per i odi c funct i on can be represent ed as a convol ut i on o f a non- per i odi c funct i on and an i mpul se train, the per i odi ci t y o f the cut t i ng pr ocess is herei n r epr esent ed as the convol ut i on of a cut t i ng- edge funct i on and the t oot h- sequence function. dr Wor kpi ece T - i / / X L ( L ) dz Z / \ / 02~ \ / Yrain \ I / ~ ] ) J ~ r ( 1 3 ) \'\/ N / \ / Y Fig. 2. Local cutting forces and cutting configuration. 162 L. Zheng et hi. 2.2 Local Cutting Force Ba s e d on t he wo r k o f Tl u s t y a n d Ma c Ne i l [1], Ko e n i g s b e r g e r a n d S a b b e r wa l [4] a nd Fu e t al . [511, t he l o c a l t a n g e n t i a l c u t t i n g f o r c e f ( 0 ) , r a d i a l c u t t i n g f o r c e fi(O), a n d a x i a l c u t t i n g f o r c e f , ( 0 ) a c t i n g on a n y c u t t i n g p o i n t o f i n f i n i t e s i ma l c ut a r e a dA ar e: f ( 0 ) = g t d A, f . ( 0 ) = K~f~(0), j ; ( 0 ) = K f ( 0 ) ( 2) wh e r e K~, Kr a n d K~ a r e r e l a t e d t o t he i n s t a n t a n e o u s c ut t h i c k n e s s . Fi g . 2 d e p i c t s t he d i r e c t i o n s o f t h e s e l o c a l c u t t i n g f or c e s . Ac c o r d i n g t o Ma r t e l l o t t i [ 13] , t he i n s t a n t a n e o u s c ut a r e a dA c a n b e r e l a t e d t o f e e d p e r t o o t h 6 a n d a n g u l a r p o s i t i o n 0: dA = 6 s i n Ow(O,[3)dz {10 w h e n 0 e [0' ([3)' 02([3)] ( 3) wh e r e w(0,[3) = o t h e r wi s e S u p p o s e t h a t t he wo r k p i e c e b o u n d a r y i n t h e Y- d i r e c t i o n i s [Ym~o, Ym~x], t he c u t t i n g e n t r y a n g l e 01([3) a n d t he e x i t a n g l e 02([3) i n t he a b o v e e x p r e s s i o n c a n b e g i v e n as: 0 ; ( Ymin "~< - - r ( [ 3 ) 0, ( [ 3) = c o s - ' - Ym~"t r ( D / k r r ; I 0 ; ( 0 4 6 ) = c o s -~ Y " ~ I k ' r r ; ( 4 ) Ymin > r(13) Ymax ~ - - 6 ) ; l Ymax[ < r ( [ 3 ) Ymax ~ r ( [ ~) 2.3 Resultant Cutting Force T h e r e s u l t a n t c u t t i n g f o r c e s F a r e t he i n t e g r a t i o n o f t he l o c a l c u t t i n g f o r c e s a l o n g t he e d g e o f c u t t e r f l ut es. Re f e r r i n g t o Fi g . 2, i t c a n b e s h o wn t hat : LF=(~b)j l f z ( 0 ) J = R f2 p (O )w (O ,[ 3 )(h ;([ 3 > T ~ h ([ 3 ))d [ 3 ( 5) wh e r e l ~ =Kt 6 1 , f i ( 0 ) = ( 1 - c o s 2 0 ) ( 6) 0 K~ s i n 0 a n d h~([3) i s t he d e r i v a t i v e o f t he c u t t i n g - e d g e h e i g h t f u n c t i o n wi t h r e s p e c t t o [3. I n t he c o n t e x t o f c u t t i n g k i n e ma t i c s , a n y mi l l i n g o p e r a t i o n c a n b e r e p r e s e n t e d b y t he d i f f e r e n c e b e t we e n t wo b a s i c c u t t i n g p r o c e s s e s wi t h t h e s a me e n t r y a n g l e o f 0 b u t wi t h d i f f e r e n t Example 1 Y~m x ( , Y ~ Workpiece Workpiece Workpiece Y= O X g t Direction of cutter movement Example 2 . Direction of cutter movement Fi g. 3. Rel at i onshi p between a mi l l i ng operation and two basic cutting processes of zero entry angle. Workpiece Work )iece Work~ uece e x i t a ngl e s . F i g u r e 3 g i v e s t wo e x a mp l e s . I n t hi s wa y , t he d e r i v a t i o n o f c u t t i n g f o r c e s f o r g e n e r a l i s e d mi l l i n g o p e r a t i o n s c a n b e s i mp l i f i e d b y c o n s i d e r i n g o n l y t h e b a s i c c u t t i n g p r o c e s s wi t h 0 a s s u mi n g v a l n e s b e t we e n 0 a n d 82(I3). Va r i o u s c u t t i n g c o n f i g u r a t i o n s , s uc h as up, d o wn , a n d s l ot c ut t i ng, can b e r e p r e s e n t e d e a s i l y b y t he b a s i c c u t t i n g p r o c e s s e s wi t h t he a p p r o p r i a t e c u t t i n g e x i t a n g l e 02([3). Th e r e f o r e , no a d d i t i o n a l e f f o r t i s n e e d e d t o t r e a t d i f f e r e n t c u t t i n g c o n f i g u r a t i o n s . Wi t h + = 2"rrfot, 0 = 2~rfov a n d 13 = 2rfo% t he wi n d o w f unc t i on w(0,13) i n e q u a t i o n ( 3) b e c o me s : w( v ( r ) =w( v ' T ) ={ l o ; 0 < ; otherwiset< TOO c o s < ( - y m j r ( ' r ) ) wh e r e T(T) = ( 7) 2'rrfo wh i c h c a n b e r e wr i t t e n as: w(v,T) = w(v,To) - ~ ~(i-l)(l) - - ~'O) (To -- 7) i i =l wh e r e To - T ~ 2 r r f \ r ( To) r(;r) ( 8) Wi t h e q u a t i o n s ( 5) a n d (8), wh i l e n o t i n g t ha t 0 = ~ b - [3 a nd v = t - ' r , t he r e s u l t a n t c u t t i n g f o r c e s c a n b e r e wr i t t e n as : F ( t ) = 27rfoI([I p ( t - . ) w( t - "r,To)(h'~('r).Tth('r))d'r - ~ f o o i! 1 1 i , ( r ( ~ r o ) r(r))(h ~ ('r)* T th ('r))d 'r)J (9) Therefore, the resultant cutting forces are expressed in the form of a convol ut i on integral in the cut t er-angl e domain. Vi a inverse Fouri er transformation, i f(+) =/ F, , ( ( b) | = 2 Xkexp(/kN(b) = ~_ lA,.~[exp(jkNtS) (10) -~LA~,kJ where Ak = 2~rfoK[FFT{p(v)w(v,To) }FFT{ h'~('r)*Tth(~r) - F F T { p ( v ) g ( i - ' ~ ( v - To)} i = I 1 i , Axk, Ask and A~k are the coefficients of the Fouri er series. They are the dynami c cutting-force component s representing the ampl i t udes and the phase angles associ at ed with the kth har- monics of t oot h-passi ng frequency. They are expressed expl i ci t l y in terms of material properties, tool geomet ry, cutting parameters, and process configuration. No integration limits for different cutting segments are needed in this model while one A Generalised Model o f Milling Forces 163 unified expressi on of cutting forces applies to the entire range of cutter rotation. The above deri vat i on procedure does not involve specific cut t i ng-edge geomet ry or mi l l i ng configuration, therefore the generality of the resulting model is warranted. The fol l owi ng case study illustrates the degeneration of the model to the specific processes of face mi l l i ng and end milling. 3. Degenerated Cases for Face Milling and End Milling 3.1 Face Mi l l i ng In a face-mi l l i ng operation, Z and 13 are both zero at the tip of an insert of a face mill. Fr om the geomet ri c relations shown in Fig. 4, the cut t i ng-edge function is det ermi ned by the combi nat i on of axial rake angl e oL A, radial rake angl e clR, l ead angl e 3'L, and radius Ro of a face mi l l as: C O S 3 ' L sin 13 tan 3' h( 13) - sin ~L. Ro, c o s 1 3 - - s m 1 3 tan 3' Ro (12) r(13) sin 7L c o s t 3 - - - s m [ 3 tan 7 where the inclination angle 3' can be obt ai ned by [14]: tan 3' = tar, aA COS 3'L -- tan c~R sin 3'L (13) Equation (12) is val i d only over the axial cutting engagement range of [0, da], while h(13) and r(13) are zero otherwise. In I | B - B A-A (X-Y PLANE) . . . . . . . . . . . . . . . . C .......... E C t E' : . IE ' \\ ] f , 7f" o S A i m v [Cutting Edge I B I 7 - - q A / I B Fig. 4. Geometry of a face-milling tooth. 164 L. Z h e n g et al. the particular case of face milling, h([3) and r([3) are non-zero over a very small range of 13. Therefore the cutting-edge function can be simplified to: 1 1 2'rro"r sin "YL Ko) r(T) Ro tan cos ~YL h('r) ~ 2" r r f o~' Ro- - , tan 3' dh('r) cos ~/e (14) h; ( ' r ) - d[3 - R t a n~ where r ( ' r o) =Ro=D/ 2. The valid range of q- herein is [0,~'] where ~r' - d ~ ( 1 5 ) COS ~L 27rfoR0 = - tan 3' In this case the Fourier transform terms involved in equation (11) can be calculated as: ( ) FFF{h~(~)+Tth('r)} = sin c Ro cs ~L, ' "r', Nkfo k tan ~ ' -r , (16) Table 1. Cutting conditions in face-milling experiment. Cutting Cutting speed d~ Y.l~n Y,;~ Feedrate number (r.p.m.) (in.) (in.) (in.) (in./min) 1 420 0.05 0.6 1.5 4 2 420 0.05 0.6 1.5 6 3 420 0.05 0,6 1.5 8 4 420 0.05 -1.5 -0.6 4 5 420 0.05 -1.5 -0.6 6 6 210 0.07 0.6 1.5 7 7 420 0.06 -0.45 0,45 4 8 420 0.06 -0.45 0,45 6 9 420 0.06 -0,45 0,45 8 l0 210 0.04 -0.435 0.435 9 11 210 0.04 -0,435 0,435 6 12 210 0,04 -0.435 0.435 4 13 420 0.05 -0.3 1.5 6 14 420 0.05 -0.3 1.5 8 15 210 0.05 -0.3 1.5 6 16 210 0.05 -0.3 1.5 8 17 210 0.05 -1.5 0.3 4 18 210 0.05 -1.5 0.3 6 19 210 0.05 -1.5 0.3 8 20 420 0.05 -1.5 0.3 4 21 420 0.05 -1.5 0.3 6 22 420 0,05 -1.5 0.3 8 23 210 0.05 -0.9 0,9 4 24 210 0.05 -0.9 0.9 8 25 420 0.05 -0.9 0,9 4 26 420 0.05 -0,9 0.9 6 27 420 0.05 -0.9 0,9 8 28 420 0.05 -1.5 -0.6 8 29 210 0.07 -1.5 -0,6 7 30 420 0.05 -0.9 0.9 10 31 420 0.05 -1.5 -0.6 9 32 210 0.04 -0,435 0,435 8 33 210 0.05 -0.9 0.9 6 F F F { p ( v ) w( v , T o ) } = ( 1 7 ) - j {si n c ( t , T o , T o , ( N k - 2)fo) - s i n c ( l , T o , } T o , ( N k + 2) j o) } {2 s i n c ( 1 , T o , T o , N k J o ) - s i n c ( 1 , T o , T o , ( N k - 2)fo) - s i n c ( 1 , T o , T o , ( N k + 2) j o) } - j {si n c ( 1 , T o , T o , ( N k - 1)fo) - s i n c ( l , T o , T o , ( N k + 1)fo) FFT{ (r(1,ro) r~r))i(h'6(7)+Tth('r))} "r'i! - e x p ( - j 2 w N k f o T ' ) (]2~rNkfo) i [ ,,@=, (/'27rNkf'r)<'~ 1 ) _ m! sin c ( 1 , ' r ' , - " r ' , N k f o ) ] } -r 5 Nfo (t8) Table 2. Cutting conditions in end-milling experiment. Cutting Cutting speed Type of da dr Feedrate number (r.p.m.) cutting (in.) (in.) (in./min) 1 420 down 0.2 0.05 2.00 2 420 down 0.2 0.05 3.50 3 420 down 0.2 0,05 5.00 4 420 down 0.2 0.05 6.50 5 420 down 0.2 0.05 8.00 6 420 up 0.2 0.05 8.00 7 420 up 0,2 0.05 6.50 8 420 up 0.2 0.05 5,00 9 420 up 0.2 0,05 3.50 10 420 up 0.2 0~05 2.00 11 420 down 0.2 0.20 4.00 12 420 up 0.2 0.20 4.00 13 420 down 0.2 0.20 3.00 14 420 up 0.2 0.20 3.00 15 420 slot 0.1 0,44 3.00 16 420 slot 0.1 0.44 4.00 17 420 up 0.2 0.30 3.00 18 420 down 0.2 0.30 3.00 19 210 down 0.2 0.05 3.00 20 210 down 0.2 0.05 5,00 21 210 up 0.2 0.05 3.00 22 210 up 0.2 0,05 5.00 23 210 up 0.1 0.05 3.00 24 210 down 0.1 0.05 3.00 25 210 down 0.1 0.10 5.00 26 210 up 0.1 0.10 3,00 27 210 up 0.1 0,10 5,00 28 420 down 0,2 0.10 8.00 29 420 up 0.2 0.10 8.00 30 210 down 0.1 0.10 3.00 31 210 down O. 1 0.05 5,00 32 210 up 0.1 0.05 5.00 33 420 up 0.2 0.10 6.50 A Generalised Model of Milling Forces 165 2 0 ' " 0 50 0 50 6 0 50 lace ~ mg No. 2S lOO 150 200 250 O . . _ J r . . ~ _ ' I . _ _ , _ o o 100 150 200 25O Fmquemy (Hz) 100 150 200 250 (Hz) o o hme ndl t ng No. 29 50 1oo 15,0 20O u0 .50 100 150 200 (Hz) 250 250 250 o o l o, ,,, J t . . . . . o f ace milling No, 30 , ~ . ~ ~ Q. ~ o 5O IOO 150 20O Frequency ( Hz ) ", , ~ gt . . . . a . . . . . . . 5o t 0 0 150 , . , Fr ~uer l cy, { Hz) , t~ 25O 200 250 . . ? . ~ . . . - . ~ = 5O t 0 0 150 2~0 25O Frequency (Hz) roi l i ng No. 31 , o , , L . ~ . . 9 ~ 9 0 , , ........ Q o so lOO 15o 10 , . . . . . . . . Frequency ( Hz) 0 5o lOO 150 r-,,,,qwcy ~ ) 6 -, , , - ~ 2 o ~ ~ o o 5o 200 250 , 9 o 2OO 250 lOO 150 2oo 250 Frequency (Hz) 0 30 g 2 ~ ,oito oLJLJ~ o 1o - - O o face rni l i ng No. 32 f ace roi l i ng No. 33 . . . . . . . . . . . . . u, 0 O- - I . _ , L _ X ' i ' ~ ,~ ? ~ , . o o o = o 100 150 200 . ~ "'~Hzt , .... 50 100 150 20O , FrecFJency ( Hz ) 50 100 150 200 Fr equent / ( Hz) O 250 250 25O 25O 2 5 0 250 ~ ) 0 ' 'J " , o so 10o 1so 2o0 60 . . . . . . . . . . . . . . . ~ "'~,xn. g ' t J ( so - - w o - 3 s o - - - 2o~ - 15 ' ,, , , , , Fmquen~ (Hz), c ~ . _t) * . . . . . . . . , : . . ~ . . e 0 50 100 150 200 F, r l mmc y (Hz) Fi g . 5. F r e q u e n c y s p e c t r u m o f p r e d i c t e d a n d me a s u r e ~ c u t t i n g f or c e s f or f ace mi l l i n g , n u mb e r s 28 t o 33. Th e c i r c l e s r e pr e s e nt p r e d i c t i o n s a n d t he s o l i d l i n e s g i v e me a s u r e me n t s , ' s l u 0 t u o J n s e o m 0 A ! ~ S ~ U ! [ p f l o s o q l p u e S U O D O ~ . p 0 J d l u ~ s 0 . ~ d o . I s ~ I ~ . I ~ o o q Z L " g g o ] 8 Z s ~ q m n u ' 2 U t ] l ~ t U p u o ~ o l S 0 O J O J 2 u ! l m o p ~ J n s e o t u p u e p ~ ] o . ~ p o J d j o t u n J l a o d s ~ ( o t l o n b o ~ t z j " 9 " ~ ! ~ l o ~ t o ~ ( ~ . d / o u m t ' e a d o o ~ o s t o o ~ o s o . O o o o ~ t ( l o t o s o o o ~ : o s ~ , o o ~ o s o , , , , , , ( z ~ ) , L ~ u e n b ~ d 0 ~ . 0 0 0 ~ ; t , ( l O t o = - - O ' ( Z H ) / , = w , ~ . ~ ' " O O ( 3 o s t o o ~ o ~ o o
( z H ) 0 ~ O ~ t O o t O S o . o " ! ' ' ' ( ~ x = ~ - , ~ ' o ~ o o o ~ t o o t o s o . . . . . . . . . 0 . . . . . . . . ' ( ~ } ~ . , a ' o ~ ~ o ~ t o o t o s o t g t t ' O N ~ p u e O , ; Z o o r , o ~ o o O O i ~ O S t O O t G { z n , . 0 ) / ~ . . . . o o ~ o s t o o t o s o s o o s o o S L o s ~ o o ~ o ~ g _ o o y ( Z H ) / n u m t ~ d o ~ t o o t o s - ' 2 , ~ - , 3 ~ - - ' , 8 ' ' ' ( Z H ) ~ = ~ ' ~ L o o | o g t o o t 6 z ' o N . 0 u r n = m m J - _ o s o ] h , o o s o o o ~ ~ . s t o s ~ o o 7 - ( Z H ) / , . - ~ e n b e . ~ d O S t o o l o s t o o t ' ( z H ~ t ~ . ~ m . b ~ . ~ " - _ 0 0 1 . O S t ~ : o s o ~ ~ ~ o I L ~ O g 0 V v - I 0 ' 0 9 o ~ o ' 0 1 r l v l a g U a ~ l Z " 7 9 9 I A Generalised Model of Milling Forces 167 f ~ e ~ mg ~ . 2 8 SO . . . . ~i "' ' ' _50L , i , , ' 2_ _!_ 0 5 0 100 1 ~ ~ ~ ~ ~ o _ ~ L I I ' I I I _ ! _ o ~ 100 ~ ~ 2 ~ ~ . m n ~ e ( d e g m l 10 , , " ' ' " ' k 1 _ ~ I , , , , ~ ~ _1_" 0 ~ 100 1 ~ ~ 2 5 0 ~ ~ ( d e g r e e ) 40O 40O 4OO ~ o m J n g N o ~ 1 0 0 . , , . , , ~- o _ 5 0 1 I ~ i I t ~ i ............ o so ~oo ~o ~oo 2~ 3o0 ~so 4o0 ~ o o , . . , , , , . ' ~ , ~ p * s r " * ) , . , ~ S O " ~ [ ~ | l t | t I I i 0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 2 0 . . ~ P ' L ~ " ) . . . . N " " ' - ' " . : ,,,~II~I [ I l I I I ' ' o s o ~ o o 1 5 0 2 0 0 2 5 0 3 0 o 3 s o 4 oo Angl e ( de gr e e ) t a c t rz~,~-~g No, 3 0 t OOr -sol r - . - . V' - . . r - - ! _SO L , l I ~ I ~ i I 0 5O 1 0 0 150 ~ 3OO 100 F , , , - 5 o so ~oo ~so 2o0 2s o ~oo 35o ~o r ~ t . m , ~ , ) . 0 - ' - 0 50 100 150 2 0 0 2 5 0 3 0 0 3 5 0 4OO 40O 4O0 l a c e m g ~ g No. 31 - 5 0 0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 3O0 3 5 0 4 0 , ' .... , , ' , , 2 0 5 0 1 0 0 1 5 0 2 9 0 2 5 0 3 0 0 3 5 O 10 , . . . . . . _ 2 0 | i ~ i i I t i 0 5 0 100 1 5 0 2 0 0 2 5 0 3OI ) 3 5 0 ( d o O m ) l 4OO m, 4OO " 4 0 0 5 0 g I 0 l a c e ~ No. 3 2 1 t i , i ! s o 100 150 200 ; so 300 350 ~ . o I . . . . 2 o ~ o " - ~ - - 2 o . . . . . 41) 0 S O 1 0 0 1 5 0 2 0 0 2 5 O 3 O 0 40O 4OO 4OO 1 0 0 , ' . . . . . . '~" 0 _ r ~ l I ~ i I I i i 0 5 0 1( ] 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 1 0 0 . ' * ~ * ' L ~ t " ' ) . . . . '~- 0 ' " : 4 0 50 l oo 150 2oo ~ 30o 3so . . . ~ . ~ r , - ) . . ........ . ............ g o , 1 I~N - 2 0 . 4 0 . . . . . . . . . . . . . " 0 5O 100 150,0 2OO 250 300 35O 4OO Fi g. 7. Pr edi ct ed and me a s ur e d cut t i ng f or ces in t he angl e doma i n for f ace mi l l i ng, numbe r s 28 to 33. Dot t ed l i nes r epr esent pr edi ct i ons and sol i d l i nes gi ve me a s ur e me nt s . 168 L. Zheng et al. ~X~ ml ng ~o. 2S SO, ~- so t i , I l i i I * , ~ ( = , i ~ l 200! , , ! * i i ~ 0 i ~001 3601 _1oo o i so 100 lSo ;so ( dl i m) (6~11 toe) ......... t 4O0 .~o 400 . . . . 0 SO 100 I ~0 200 250 ~o ~, ~ 5O 50 100 150 2OO 2SO 300 ~SO 0 .." .. '" ." ~ ' 0 5 0 1 0 0 1SO 2 0 0 2 5 0 3 0 0 3 ~ ..... t end rOling No. 30 2 o I "-=I Y , , , _ , . . , _ 2 i J I i i I u SO 1 ~ 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 l o o I ' n i i i n I h m -500 50 100 150 200 250 300 Ido~eo) (dllltNl o ~ . 3 ~ ~ ' 0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 ~ 0 - ~ 5O 100 / - , , . / - . , . / , . n I i I i 150 2O0 2SO 3~ ( ~) - 1 0 50 100 150 200 250 300 350 1 0 0 . . . . . . . o - ~ 0 SO 1 0 0 1 5 0 2 0 0 ~ ~ (deom) 1 0 ~ , , ' . . . . (a, Qm) 1 0 , ' . . . . . u . - 1 0 ~ v t n l i t t 1 " i ma ~ i l l ~ . aa s o 100 1 s o 2 o o I ! ~ a ~ " 2 0 0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 ~--2o . ~ , ,._ ~ , - - ~ , ~ , 0 5 0 10010 1 5 0 2 0 0 2 5 0 ~ ( d i l ~ n w ) i 4 0 1 1 Fi g. 8. Predi ct ed and me a s ur e d cut t i ng f or ces i n t he angl e domai n for end mi l l i ng, numbe r s 28 to 33. Dot t ed l i nes r epr esent pr edi ct i ons and sol i d l i nes gi ve me a s ur e me nt s . Tabl e 3. Calibrated K, K~ and K, with respect to average cut thickness in the experiments. Face milling End milling Kt =4.033(_~c)~.2s~ x 1041b in. 2 K = 8.965(~)-o.t~ x 1041bin. 2 K~ = 0.121 (t_~) 4~22~ K~ = 0.3 t 0(~) ~-~ K~ = 0. 276( t J 143 K~ = 0.702(t~) 217 FFT[p(v)g(i-I~(v - To)] = 1. "2 - aj { (j "rr(Nk - 2)fo) (~-~ ~ e x p ( - j 2 ~ r T o ( N k - 2)fo) - ( j 2 " r r ( N k + 2 ) f J i - ~ ) e x p ( - j 2 ~ r T o ( N k + 2)fo)} { 2 ( j 2 7 r N k J o ) ( ~ - l ) e x p ( - j 2 w T o N k f o ) - ( j 2v( Nk - 2)jo) (i-~ ~ e x p ( - j 2 ~ r T o ( N k - 2)fo) (19) - ( j 2 ~ r ( N k + 2)fo) (i I ) e x p ( - j 2 7 r T o ( N k + 2)fo)} - ~ j { ( j 2 7 r ( N k - 1 ) f o ) ( ~ - l ) e x p ( - j 2 ~ r T o ( N k - l)fo) - 0'2"rr(Nk + 1 ) ~ o ) ( i - I ) e x p ( - j 2 ~ r T o ( N k + l)fo) wher e WA sin(~r Wwf) sin c ( W A , W w , W o f l - e xp( - j 2wWc J ) ~rf (20) Ther ef or e, t hrough equat i on ( I 1) t he dynami c cut t i ng- f or ce component s in face mi l l i ng are expl i ci t l y expr essed as funct i ons of cut t i ng pressure coeffi ci ent s, face mi l l geomet r y, cut t i ng par amet er s and cut t i ng confi gurat i on. The cut t i ng forces in t he angl e domai n can be r econst r uct ed f r om equat i on (10). Tabl e 4. Cutting conditions used in comparison [2]. A G e n e r a l i s e d M o d e l o f M i l l i n g F o r c e s 3. 2 End Mi l l i ng 1 6 9 The val ues of Z and 13 are also zer o at t he tip of an end- mi l l flute. For a hel i cal end mi l l wi t h const ant radi us Ro and const ant hel i x angl e c~, its cut t i ng- edge f unct i on i s : Ro r ( 1 3 ) = R o = D / 2 , h([3) = tan c~ 13 (21) They are val i d onl y over t he axial cut t i ng engagement r ange o f [0, da]. Ther ef or e: 1 1 = 0 , r(%) r("r) hi (T ) = t a nc ~; 0 <--- ~ --< 7' d~t an( ~ [ ~ ot her wi se wher e q ' ' - 2q_rfoRo (22) So equat i on (11) is changed to: A k = 2 7 r f o I ~ [ F F T { p ( v ) w ( v , T o ) } F F T { h ; ( ' r ) * r t h ( T ) } ] (23) wher e / . o F F T { h ' ~ ( ' r ) * T t h ( ' r ) } = sin C\ t an a ' ~r', "r', (24) and F F F { p ( v ) w ( v , T o ) } of end mi l l i ng is the same as that of face mi l l i ng, whi ch is gi ven by equat i on (17). The cut t i ng forces in t he angl e domai n can be achi eved by equat i on (10). The second part of t he dynami c cut t i ng- f or ce component s of equat i on (11) is associ at ed wi t h t he vari at i on of cut t i ng engage- Cutting parameters Case 1 Case 2 Mode of milling Up cut Down cut Diameter of end mill 19.05 mm (0.75 in.) I9.05 mm (0.75 in.) Helix angle of end mill 30 30 Number of flute 4 4 K t 5 4 6 ( t c ) - _ ' 2 4 6 MPa K~ = 437(tc) -0'343 MPa (7.919[tc) ~246 x 104 tb in, -2) (6.338(tc) ~-3~3 x 104 lb in. -2) Kr 0.270(t) 27~ 0.180(t) ---z49 Cutting speed 478 r.p.m. 478 r.p.m. Feedrate 0.14 mm/tooth (0.0055 i.p.r.) 0.14 mm/tooth (0.0055 i.p.r.) Radial depth of cut dr 9.525 mm (0.375 in.) 9.525 mm (0.375 in.) Axial depth of cut d~ 19.05 (ram) (0.75 in.) 21.59 mm (0.85 in.) Tabl e 5. Comparison of current model predictions to experimental data in Budak et al. [2]. Cutting type Case 1 Case 2 Force F,~ Fy Fx Fy Valley Peak Valley Peak Valley Peak Valley Peak Predictions (iV) 1301 Experiments (N) in [2] 1300 Absolute error (%) 0.1 1856 432 1251 -343 -670 1570 2146 1750 500 1250 - 350 -600 1700 2000 5.7 18.2 0.1 2.0 10.4 8.3 6.8 170 L. Zheng et al. C a s e 1 - simulation 2000 . . . . . . ~ 1500 10000 50 100 150 200 250 Angl e ( d e g r e e ) 1 5 0 0 F , ' . . . . . . z _ g 1 0 0 ~ ~soo ~ 0 50 100 150 200 250 300 3 5 0 An@e ( dec#ee) , , - 400 . . . . u. -6 0 0 7 o"11 ~ , , , , _ I , - ~ ' 0 50 100 150 200 250 300 35u Angl e ( degr ee) 4OO 400 l 400 C a s e 2 - simulation - 2 0 0 , "' , . . . . ' u. - 600 _aoo L , , , , , _,__ __'. 0 50 t 00 150 200 250 300 3 5 u Angl e ( d e g r e e ) 2500 ' , ~ . . . . ' 5 i i ~ i i t 0 An g l e ( degr ee) - 5 0 0 . . . . . . . ~ -6 0 0 i i i i i , ' _700 t , - , , t _' _ _' . . 2 ^ 0 5 0 100 150 200 250 300 Angl e (degrS~) Fig. 9, Simulation results of cutting forces. .... t 400 merit time, and it is zero herein because of the constant radial positions of the cutting edge. experiments, while a hi gh-speed steel end mill, with a di amet er of 7 in., helix angle of 30 , and 4 flutes, was used in the end mi l l i ng experiments. The workpi ece material is Al umi ni um 6061 in both experiments, Face-mi l l i ng and end-mi l l i ng tests were carried out under 33 different conditions each, as shown in Tables l and 2, respectively. The first 27 tests were used to calibrate Kt, Kr and K, for each experiment. Fol l owi ng the scheme documented in Zheng et al. [15], the specific cutting pressure coefficients (Kt, K~, and K~) with respect to average cut thickness were det ermi ned regressionally and are shown in Tabl e 3. The remai ni ng 6 cutting tests in each mi l l i ng operation were used to verify the analytical cutting force models. The fre- quency spectra of the predi ct ed and measured cutting forces in the X-, Y-, and Z-di rect i ons are shown in Fi gs 5 and 6 for face mi l l i ng and end milling, respectively. It can be seen that the predi ct ed dynami c cutting-force components agree well with the measured ones. Note that the identification of K, Kr, and /Ca i nvol ved curve fitting, thereby inducing a source of predi ct i on error. Ideal l y, the force spectra ought to be non- zero onl y at the harmonics of tooth-passing frequency. The mi nor peaks observed at the harmonics of the spindle frequency in the measured dat a are attributed to the unmodel l ed disturb- ance of cutter-axis offset [12]. The predi ct ed and measured cutting forces in the angl e domai n are shown in Fi gs 7 and 8 for face milling and end milling, respectively. The predi ct ed and measured waveforms agree well in terms of ampl i t ude and pulsation period. The effect of cutter axis offset is again observed from the repeated tooth-passing patterns, especi al l y in the case of face milling. The slight discrepancies of ampl i t ude are bel i eved to be caused by the variances in the specific cutting pressure coefficients along with the mi nor presence of cutter-axis offset. Addi t i onal l y, the current model is compared to other docu- mented methods in the literature. The cutting conditions studied by Budak and Altintas [2] are listed in Tabl e 4. The predi ct ed peak and val l ey values of force in the X- and Y-di rect i ons are listed in Tabl e 5 in compari son to experi ment al data in [2] along with the associ at ed en' ors. The average and maxi mum absolute percentage errors are 4.4 and 18.2, respectively. The simulation results of cutting forces are shown in Fi g. 9. 5. Conc l us i ons 4. Exper i ment al Ver i f i cat i on and Si mul at i on To verify the anal yt i cal model, face- and end-mi l l i ng experi- ments have been performed on a vertical mi l l i ng machine. A Kistler pl at form dynamomet er was mounted between the work- pi ece and machining table to measure cutting forces. The measurement was sampl ed at a rate of 2000 points/second and then tow-pass filtered at a cut -off frequency of 250 Hz to eliminate high-frequency component s attributed to machine tool dynami cs and electrical noise. A face-mi l l i ng cutter, with a di amet er of 3 in., axi al rake angle of e~ A = 2 , radial rake angle of c~R = 5 , l ead angle of -& = 2 , and 4 carbide inserts, was used in the face-mi l l i ng A general i sed cutting force model for mi l l i ng operations has been developed. Based on the relationship between the local cutting forces and the instantaneous chip load, the analytical integration of the l ocal cutting forces gi ves the resultant cutting forces in the angle domain. The intermittent radial engagement is model l ed by a unit rectangular wi ndow with a variant width associated with the radial posi t i ons of the cutting edge. A Fouri er transformation achieves a cl osed-form expressi on of the cutting-force component s at the harmonics of tooth- passi ng frequency. By virtue of its cl osed-form nature, the model allows for process planning, tool optimisation, and on-l i ne diagnostics. In addition, the devel opment procedure uses a general i sed cutting- edge function without i nvol vi ng specific cutter geomet ry and A Generalised Model of Milling Forces I71 pr ocess confi gurat i on, t her eby war r ant i ng t he gener al i sat i on of t he model . Face and end mi l l i ngs wer e used as exampl es t o show t he appl i cabi l i t y of t he gener al i sed model . Exper i ment al t est i ng was per f or med to ver i f y t he cut t i ng- f or ce model s in t he cont ext o f angl e domai n wa ve f or m and f r equency domai n component s. Compar i son to ot her document ed dat a in t he l i t erat ure has also been di scussed. I4. M. Kronenberg, "The inclination of cutting edge and its relation to chip curling", Tool Engineering, 14(9), pp. 12-15, 1945. 15. Li Zheng, Yun Shun Chiou and S. Y. Liang, "Three dimensional cutting force analysis in end milling", International Journal of Mechanical Sciences, 37, 1-11, 1995. Not at i on C~ Ref er ences ~A,C~R 1. J. Tlusty and P. MacNeil, "Dynamics of cutting forces in end milling", C1RP Annals, 24, pp. 21-25, 1975~ 2. E. Budak and Y. Altintas, "Peripheral milling conditions for g(i-l~(v-7o) improved dimensional accuracy", International Journal of Machine + Tools Manufacturing, 34(7), pp. 907-918, 1994. ~L, 3. E. Budak and Y. Altintas, "Modeling and avoidance of static tbrm 0 errors in peripheral milling of plates", International Journal of Machine Tools Mamfacturing, 35(3), pp. 459-476, 1995. 0~, 0 2 4. F. Koenigsberger and A. J. P. Sabberwal, "An investigation into v~ the cutting force pulsation during milling operations", International A Journal of Machine Tool Design and Research, 1, pp. 15-33, 1961. Axk, A~k, Azk 5. H. J. Fu, R. E. DeVor and S. G. Kapoor, "A mechanistic model for the prediction of the force system in face milling operations", da,dr Transactions ASME Journal of Engineering for Industry, 106, dA pp. 81-88, February 1984, D 6. W. A. Kline, R. E. DeVor and J. R. Lindberg, "The prediction fo of cutting forces in end milling with application to cornering f , fr, f~ cuts", International Journal of Machine Tool Design and Research, 22(1), pp. 7-22, 1982. f~, ~., f~ 7. J. W. Sutherland and R. E. DeVor, "An improved method for F~, Fy, F: cutting force and surface error prediction in flexible end milling systems", Transactions ASME Journal of Engineering for Industry, -F 108, pp. 269-279, November 1986. h~ 8. E. J. A. Armarego and N. P. Deshpande, "Computerized end milling force predictions with cutting models allowing eccentricity h([3) and cutter deflections", CRIP Annals, 40(1), pp. 25-29, 1991. H 9. A. E. Bayoumi, G. Yucesan and L. A. Kendall, "An analytic K~, K~ mechanistic cutting force model for milling operations: a theory and methodology", Transactions ASME Journal of Engineering K_t for Industry, 116, pp. 324-330, August 1994. K 10. A. E. Bayoumi, G. Yucesan and L. A. Kendall, "An analytic /5 mechanistic cutting force model for milling operations: a case N study of helical milling operation", Transactions ASME Journal r(13): of Engineering for Industry, 116, pp. 331-339, August 1994. R l 1. I. Yellowley, "A note on the significance of the quasi-mean T resultant force and the modeling of instantaneous torque and forces To in peripheral milling operations", Transactions ASME Journal of T_th(13) Engineering for h~dust~', 116, pp. 331-339, August I994. t~ 12. S. Y. Liang and J. J. Wang, "Milling force convolution modeling t~ for identification of cutting axis offset", International Journal of WA, Ww, Wc Machine Tools Manufacturing, 34(8), pp. 1 I77-1 t90, 1994. W(0,13) 13. M. E. Martellotti, "An analysis of the milling process", Trans- Ymin, Ym~ actions ASME Journal of Engineering for Industry, pp. 667-700, 1941, Zmin, Zmax convolution operator helix angle of an end mill axial and radial angles of a face mill angular position of any cutting point in the cylindrical coordinate system unit area impulse function ( i - 1)th derivative of ~( v - To) with respect to v angular position of cutter in the negative Y-direction lead and inclination angles of a face mill angular position of any cutting point in the negative Y-direction entry and exit angles upper limit of cutting edge function in terms of "r as defined in equation (10) kth harmonics of cutting forces in the X-, Y-, and Z-directions axial and radial depth of cut instantaneous cut area diameter of cutter frequency of spindle local cutting forces in the tangential, radial, and axial directions local cutting forces in the X-, Y-, and Z-directions resultant cutting forces in the angle domain in the X-, Y-, and Z-directions as defined in equation (5) derivative of height function of cutting edge with respect to [3 height function of one cutting edge with respect to [3 height of any cutting point radial-to-tangential and axial-to-tangential cutting force ratios tangential cutting pressure constant as defined in equation (6) as defined in equation (6) number of cutting edges radius function of one cutting edge with respect to 13 radius of any cutting point cutting engagement time function of any cutting point cutting engagement time of the cutting point at 13 = 0 tooth sequence function average cut thickness feed per tooth amplitude, width and centre of a window function unit rectangular window function minimum and maximum positions of workpiece in the Y-direction integration limits in the Z-direction