Chinese

Journal of
Chinese Journal of Aeronautics 20(2007) 282-288
Aeronautics
www.elsevier.com/locate/cja

New Cutting Force Modeling Approach for Flat End Mill

WAN Min*, ZHANG Wei-hong, TAN Gang, QIN Guo-hua
Sino-French Laboratory of Concurrent Engineering, The Key Laboratory of Contemporary Design & Integrated Manufacturing
Technology, Northwestern Polytechnical University, Xi' an 710072, China

Received 10 May 2006; accepted 15 August 2006

Abstract

A new mechanistic cutting force model for flat end milling using the instantaneous cutting force coefficients is proposed. An
in-depth analysis shows that the total cutting forces can be separated into two terms: a nominal component independent of the runout and
a perturbation component induced by the runout. The instantaneous value of the nominal component is used to calibrate the cutting force
coefficients. With the help of the perturbation component and the cutting force coefficients obtained above, the cutter runout is identified.
Based on simulation and experimental results, the validity of the identification approach is demonstrated. The advantage of the proposed
method lies in that the calibration performed with data of one cutting test under a specific regime can be applied for a great range of
cutting conditions.

Keywords: runout; cutting force; flat end mill; calibration; cutting force coefficient

Modeling of cutting forces constitutes the basis
for machining simulations, such as the prediction of
surface quality, cutter wear and machine-tool vibra-
tion[1-4]. It is recognized that the magnitude and dis-
tribution of the cutting forces are greatly affected by
cutter runout, which is a common phenomenon in
multi-fluted[1] end milling operations. To ensure
prediction accuracy, extensive research effort[5-13]
has been sacrificed to establish a reliable cutting
force model.*
In the early studies of the milling process[5-9],
the cutting force models were developed based on
the nominal instantaneous uncut chip thickness
without runout. More accurate milling force models
were proposed in Refs.[10-13] in order that the ef-
fect of runout is included.
*Corresponding author. Tel.: +86-29-88495774.
E-mail address: m.wan@nwpu.edu.cn
Foundation items: National Natural Science Foundation of China
(50435020); Natural Science Foundation of Shaanxi Province(2004E217);
the Doctorate Creation Foundation of Northwestern Polytechnical Uni-
versity (CX200411); Youth for NPU Teachers Scientific and Technologi-
cal Innovation Foundation
In practice, runout parameters exist and are
usually difficult to measure because the milling
process is a dynamic coupling process. As cutting
forces measured by a dynamometer clearly reveal
the influence of the cutter runout, they can be natu-
rally used to estimate the cutter runout[14-17]. From
this viewpoint, Armarego and Despande[14] pro-
posed an iterative algorithm to estimate the value of
the cutter runout. Using convolution integration
method and lumped shearing force model, Zheng
and Wang et al.[15-16] determined the runout through
force analysis in frequency domain. A common
point of these methods is that cutting force coeffi-
cients are calibrated using the average cutting forces.
In contrast to the above work, an alternative ap-
proach proposed by Cho et al.[17] is to use instanta-
neous cutting force for the calibration of cutting
force coefficients and the evaluation of runout pa-
rameters in end milling.
This paper presents a new approach to identify
the instantaneous cutting force coefficients and ra-
 WAN Min et al. / Chinese Journal of Aeronautics 20(2007) 282-288 · 283 ·

dial cutter runout in flat end milling. Theoretically,

it is demonstrated that the total cutting forces are
separated into two components in angular domain: a
nominal component independent of the cutter runout
and a perturbation component induced by the runout.
The instantaneous value of the nominal component
is used to calibrate the cutting force coefficients.
With the help of the perturbation component and the
cutting force coefficients obtained above, the runout
is identified. The advantage of the proposed method
lies in that the calibration procedure is performed
with only a few tests needed. This can reduce the
burden of a large number of experiments required in
ordinary calibration methods. The validity of the
proposed approach is verified by comparing the
predicted cutting forces with the experimental re-
sults.

1 Model Formulation Fig.1 End milling and coordinate systems.

1.1 Basic cutting force model ter rotation angle ϕ are obtained by summing the
forces acting on all cutting edges as follows
An end milling process is illustrated in Fig. 1. N
The cutting forces applied on element Q of cutting Fs (ϕ ) = ∑ Fi ,s (ϕ ) s = X, Y, Z (3)
i =1
edge i, whose elementary length is dz, can be di-
where N is the total teeth number. When runout oc-
vided into three components: tangential force
curs, hi (z ) needs to be calculated in terms of the
dFi ,t ( z ) , radial force dFi ,r ( z ) and axial force
actual rotation radius of each cutting edge element
dFi , z ( z ) . These can be calculated using
and the feed per tooth. Due to the occurrence of
dFi ,t ( z ) = K t hi ( z ) dz ⎫
⎪ cutter runout, the rotation radius of an arbitrary
dFi ,r ( z )= K r hi ( z ) dz ⎬ (1)
⎪ element of cutting edge i with respect to axial posi-
dFi , z ( z )= K z hi ( z ) dz ⎭
tion z can be obtained as[10,13]
where hi ( z ) is the instantaneous uncut chip thick- ⎡ 2(i − 1)π ⎤
Ri ( z ) = R + ρ cos ⎢λ − κ ( z ) − (4)
ness associated with element Q. K t , K r and K z ⎣ N ⎥⎦
are three cutting force coefficients. with
The total X-, Y- and Z-force components acting z tan β
κ ( z) = (5)
R
on cutting edge i at a certain cutter rotation angle ϕ
where, R and β are the nominal geometry radius
are expressed as follows
and helical angle of the cutter, respectively. ρ and
Fi , X (ϕ )= ∫ hi ( z )[− K t cos θ ( z ) − K r sin θ ( z )]dz ⎫⎪
zi ,u

zi ,l
λ are the runout parameters as shown in Fig.2.
⎪
z ⎪ In general, the calculation of hi (z ) associated
Fi ,Y (ϕ )= ∫ hi ( z )[ K t sin θ ( z ) − K r cos θ ( z )]dz ⎬ (2)
i ,u

z
i ,l
⎪ with an arbitrary element Q (see Fig.1) can be writ-
z
Fi , Z (ϕ )= ∫ K z hi ( z ) dz
i ,u ⎪
⎪⎭ ten as in Refs.[10,12-13].
z
i ,l

hi ( z ) = mi f z sin(θ ( z )) + Ri ( z ) − Ri − m ( z ) (6)
in which zi ,l and zi ,u represent the immersion boun- i

daries depending upon the immersion of cutting where mi means that the current tooth i is remov-
edge i. The total instantaneous cutting forces at cut- ing the material left by the mi-th tooth previous.
· 284 · WAN Min et al. / Chinese Journal of Aeronautics 20(2007) 282-288

By substituting Eq.(9) into Eq.(8), dividing

Eq.(8) by N, and subsequently performing integra-
tion along z, it is obtained that
⎡ FX (ϕ ) ⎤ ⎡ A − B 0 ⎤ ⎡ K t (ϕ ) ⎤
⎢ ⎥ fz R ⎢
⎢ FY (ϕ ) ⎥ = ⎢B A 0 ⎥⎥ ⎢⎢ K r (ϕ ) ⎥⎥ (10)
⎢ ⎥ tan β
⎣⎢ FZ (ϕ ) ⎦⎥ ⎣⎢ 0 0 −C ⎦⎥ ⎣⎢ K z (ϕ ) ⎦⎥
where constants A, B and C denote the integral re-
sults given below
1 N θ
( 1 N
)
θ
A = ∑ cos 2θ θ ; B = ∑ [(2θ − sin 2θ ) θ ]
4 i =1 4 i =1
i ,u

i ,l
i ,u

i ,l

(11)
( )
N
θ
Fig.2 Geometry of the cutter runout. C = ∑ cos θ θ i ,u

i ,l
i =1

By reviewing Eqs.(4) and (5) together, Eq.(6) In Eq.(10), assume that the cutting force coef-
can be further developed as ficients are constant at the given cutter rotation an-
mi π 2(i − 1)π
hi ( z ) = mi f z sin (θ ( z )) + [−2mi ρ sin ( )⋅ gles ϕ + ( i = 1, 2, ···, N ). Different angles
N (7) N
(2i − mi − 2)π 2(i − 1)π
sin (λ − κ ( z ) − )] ϕ+ correspond to different coefficients.
N N
1.2 Determinations of the instantaneous Note that θi ,l and θi ,u correspond to lower
cutting force coefficients and upper angle bounds of the immersion cutting
edge i, respectively.
At the given cutting instant shown in Fig.1, the
Eq.(10) is just the nominal cutting force com-
angular position corresponding to cutting edge ele-
ponents Fs (ϕ ) (s = X, Y, Z) that only depend upon
ment Q with axial coordinate z, is θ (z) . Obviously,
cutting force coefficients and the feed per tooth no
after a cutter rotation with an angle of (2iπ)/N (i=1,
matter what the runout is. Assume that FsM (ϕ ) (s =
2, ···, N–1), the angular position of the cutting edge
X, Y, Z) denote the measured values of cutting
element of the cutting edge (i+1) that has the same
forces at cutter rotation angle ϕ . Fs (ϕ ) can be
axial coordinate z equals θ (z), too. As a result, the
obtained by averaging the measured values over one
sum of all X-, Y- and Z- forces of the cutting edge
cutter revolution.
elements with respect to the angular position θ (z)
1 N ⎡ 2(i − 1)π ⎤
can be obtained by Fs (ϕ ) = ∑ ⎢ FsM (ϕ + )⎥ (12)
N i =1 ⎣ N ⎦
dFX ( z ) =[− K t cos θ ( z ) − K r sin θ ( z )] h[θ ( z )]dz ⎫
⎪ Finally, with the known values of Fs (ϕ ) , K t ,
dFY ( z ) = [ K t sin θ ( z ) − K r cos θ ( z )] h[θ ( z )]dz ⎬ (8)
dFZ ( z ) = K z h[θ ( z )]dz ⎪ K r and K z can be deduced immediately from
⎭
Eq.(10) by the inverse of coefficient matrix. This
with
N provides the possibility to investigate the instanta-
h[θ ( z )] = ∑ (mi f z sin (θ ( z )) + Ri ( z ) − Ri − mi ( z )) neous variations of the cutting force coefficients.
i =1 (9)
= N f z sin (θ ( z )) 1.3 Identifications of the cutter runout
where Ri − m ( z ) = RN ( z ) if i–mi = 0. parameters
i

It is important to see that the effect of cutter
radial runout on h[θ ( z )] vanishes. It turns out that
the sum of all X-, Y- and Z-forces of the cutting edge
elements with the same angular position θ (z) is in-
dependent of the runout.
After the identifications of cutting force coeffi-
cients, results can be now used to determine the
cutter runout. By substituting Eq.(7) into Eq.(2), the
total X-, Y- and Z-force components acting on cut-
ting edge i in a considered instantaneous state with
 WAN Min et al. / Chinese Journal of Aeronautics 20(2007) 282-288 · 285 ·

2(i − 1)π ⎡ FX (ϕ i ) − FX (ϕ i ) ⎤
cutter rotation angle ϕi = ϕ + (0 ≤ ϕ ≤ ⎡V11 (ϕ i ) V12 (ϕ i ) ⎤
N ⎢V (ϕ ) V (ϕ ) ⎥ ⎡ ρ cos λ ⎤ = ⎢ F (ϕ ) − F (ϕ ) ⎥ (15)
i ⎥⎢ ⎢ i ⎥
2π/N) correspond to ⎢ 21 i 22
⎣ ρ sin λ ⎥⎦ ⎢ Y i Y
⎥
⎢⎣V31 (ϕ i ) V32 (ϕ i ) ⎥⎦
⎢⎣ FZ (ϕ i ) − FZ (ϕ i ) ⎥⎦
⎡ Fi , X (ϕi ) ⎤ ⎡ A1 (ϕi ) − B1 (ϕi ) 0 ⎤
⎢ ⎥ fz R ⎢ with
F (ϕ ) = B (ϕ ) A (ϕ ) 0 ⎥i
⎢ i ,Y i ⎥ ⎢ 1 i 1 i ⎥ N N ⎫
⎢ F (ϕ ) ⎥ tan β Vk1 (ϕi ) = cos α ∑ Ek1 (ϕi ) + sin α ∑ Ek 2 (ϕi ) ⎪
⎢
⎣ 0 0 − C (ϕ ) ⎦⎥ (13)
⎣ i, Z i ⎦ 1 i
i =1 i =1 ⎪
⎬ (16)
⎡ K t (ϕi ) ⎤ ⎡ E11 (ϕi ) E12 (ϕi ) ⎤ N N
⎢ K (ϕ ) ⎥ + ⎢ E (ϕ ) E (ϕ ) ⎥ ⎡ arunout ⎤ Vk 2 (ϕi ) = cos α ∑ Ek 2 (ϕi ) − sin α ∑ Ek1 (ϕi ) ⎪
⎢ r i ⎥ ⎢ 21 i 22 i ⎥ ⎢ ⎥ ⎪
b i =1 i =1 ⎭
⎢⎣ K z (ϕi ) ⎥⎦ ⎢⎣ E31 (ϕi ) E32 (ϕi ) ⎥⎦ ⎣ runout ⎦
(k = 1, 2, 3)
where By means of K t (ϕi ) , K r (ϕi ) and K z (ϕi )
2R π whose values are estimated using the procedure
E11 (ϕi ) = sin( )[ K t (ϕi ) A1 (ϕi ) − K r (ϕi ) B1 (ϕi )]
tan β N given in the previous section, the runout parame-
2R π ters can be derived directly from Eq.(15). In most
E12 (ϕi ) = sin( )[− K t (ϕi ) D1 (ϕi ) + K r (ϕi ) A1 (ϕi )]
tan β N cases, as the measured data involves noise signals,
2R π FXM (ϕ i ) , FYM (ϕ i ) and FZM (ϕ i ) become all per-
E21 (ϕi ) = sin( )[ K t (ϕi ) B1 (ϕi ) + K r (ϕi ) A1 (ϕi )]
tan β N turbed at the same cutter rotation angle. Conse-
2R π
E22 (ϕi ) = sin( )[− K t (ϕi ) A1 (ϕi ) − K r (ϕi ) D1 (ϕi )] quently, the computing accuracies of ρ and λ may
tan β N
be strongly influenced if Eq.(15) is directly used.
2R π
E31 (ϕi ) = sin( ) K z (ϕi )C1 (ϕi ) Cutting forces of different tooth periods will be
tan β N
chosen to solve ρ and λ so that the influence of
2R π
E32 (ϕi ) = − sin( ) K z (ϕi ) E1 (ϕi ) noise signals can be weakened to the lowest degree.
tan β N
arunout = ρ cos γ ; brunout = ρ sin γ In general, the component that has the largest peak,
with e.g., FYM , is adopted to derive the computing
1 1 scheme. Using the values of FYM at the cutter rota-
θ θ
A1 (ϕi ) = cos 2θ θi ,u ; B1 (ϕi ) = (2θ − sin 2θ ) θi ,u 2(i − 1)π
4 i ,l 4 i ,l
tion angles ϕi = ϕ + (i=1, 2, ···, N), the
θi ,u 1 θi ,u
N
C1 (ϕi ) = cos θ θ ; D1 (ϕi ) = (2θ + sin 2θ ) θ following expression of compact form is obtained,
i ,l 4 i ,l

θ (2i − 3)π ⎡g ⎤
E1 (ϕi ) = sin θ θi ,u ; γ = λ − θi ,u − φi − T ⎢ 1 ⎥ = TF (17)
i ,l N ⎣ g2 ⎦
here, φi is obtained in the following way. where
If θi,u ≤ π, φi = 0 . ⎡ V21 (ϕ1 ) V22 (ϕ1 ) ⎤ ⎡ FYM (ϕ1 ) − FY (ϕ ) ⎤
⎢ ⎥ ⎢ ⎥
Else if θi,u > π , ⎢ ⎥
⎢ ⎥
Rr − R π 2(i − 1)π T = ⎢ V21 (ϕi ) V22 (ϕi ) ⎥ ; TF = ⎢ FYM (ϕi ) − FY (ϕ ) ⎥ ;
φi = ϕ − ϕ0 − arcsin ( )− − ⎢ ⎥
R 2 N ⎢ ⎥
⎢ ⎥ ⎢ ⎥
Evidently, the first term of the right hand side ⎢⎣V21 (ϕ N ) V22 (ϕ N ) ⎥⎦ ⎢ ⎥
⎢⎣ FYM (ϕ N ) − FY (ϕ ) ⎥⎦
in Eq.(13) refers to a nominal component without
cutter runout whereas the second term refers to the g1 = ρ cos λ ; g 2 = ρ sin λ
force components due to cutter runout. Based on the least square theory, g1 and g 2
Assume that can be obtained as follows
(2i − 3)π ⎡ g1 ⎤ −1
α = −θi ,u − φi − ⎢ g ⎥ = ⎡⎣T T ⎤⎦ ⎡⎣T TF ⎤⎦
T T
(14) (18)
N ⎣ 2⎦
Combing Eqs.(3), (10) and (13), the following Subsequently, ρ and λ can be determined easily by
expressions can be obtained, the following expressions
· 286 · WAN Min et al. / Chinese Journal of Aeronautics 20(2007) 282-288

g2 g g N θi ,u
λ = arctan(
g1
), ρ = 1 or ρ = 2
cos λ sin λ
(19) ∑ [∫ θ f z sin θ dθ ]
i =1 i ,l
h(ϕ ) = N
(20)
Note that the correct λ should give rise to a
∑ (θi,l − θi,u )
positive value of ρ. However, from the above pro- i =1

cedure, it can be seen that a set of ρ and λ can be
available for each value of cutter rotation angle. For
this reason, the real set of runout parameter is se-
lected to be such a one that minimizes the squared
difference between the simulated and measured cut-
ting forces at all sampling instants.
In the particular case of N = 2, T TT will be-
come singular in Eq.(18). ρ and λ can be optimally
selected to be those that satisfy Eq.(15) and mini-
mize the squared difference between the simulated
and measured cutting forces at all sampled instants.
For a single flute cutter with N = 1, the cutting
forces are not influenced by the runout.
2 Experimental Verifications
Now, a series of cutting tests are carried out to
determine the cutting force coefficients and runout
parameters. A three-fluted flat end mill with a di-
ameter of 16 mm and a helix angle of 30° is used
and set up on a vertical CNC milling machine. Cut-
ting forces are measured with a Kistler 9255B dy-
namometer. The workpiece material is Al 2618.
Relevant cutting conditions are listed in Table 1.
It is found that the cutting force coefficients
have a tendency of varying dramatically and be-
come large in most cases when the chip thickness
becomes small. This is the so-called size effect[7].
Historically, many researchers, e.g., Altintas et
al.[1,7], utilized the relationship between the cutting
force coefficients and the average chip thickness to
reveal the size effect. Cutting force coefficients are
then calibrated using the average cutting forces that
need, however, a large number of cutting tests. In
this work, the cutting force coefficients K q (ϕ ) (q =
t, r, z) are obtained based on the instantaneous cut-
ting state, instead. Compared to the above model, a
relationship will be established between K q (ϕ ) and
the instantaneous average chip thickness h(ϕ ) .

Table 1 Cutting conditions

Axial
Radial
depth Feed per Rotation
Test Milling depth of Fig.3 Comparisons of Kq(q=t, r, z) and the
of cut tooth fz /(mm speed/
No. type cut Rr/
Rz / per tooth) (r·min–1) fitted values.
mm
mm
1 Down 8 1 0.05 2 000 From Fig.3, it can be seen that an expo-
2 Down 3 8 0.066 7 3 000
3 Down 8 1.3 0.1 5 000 nent-like relation exists between cutting force coef-
4 Up 2 8 0.075 4 000
ficients Kq and h(ϕ ) . For this reason, the relation-
Cutting forces measured in Test 1 are used to ship between Kq and h(ϕ ) is fitted by the follow-
determine the cutting force coefficients. All the re- ing nonlinear fitting function
[W h (ϕ )]
maining tests will be used to verify the proposed K q = Wq1 + Wq 2 e　q 3 (q = t, r, z) (21)
scheme. Based on the proposed approach, the cali- The fitted coefficients are also illustrated in Fig.3,
brated values of Kq (q = t, r, z) are shown in Fig.3 the overall trend of the fitted results corresponds
versus the instantaneous average chip thickness well to the discrete values calculated.
h(ϕ ) that can be calculated at the specified cutter With the aid of the Kq calibrated, results of ρ
rotation angle ϕ by and λ identified from Eq.(19) are as follows
 WAN Min et al. / Chinese Journal of Aeronautics 20(2007) 282-288
ρ = 5.2 μm , λ = 60.5 (22)
Now, the remaining cutting tests No.2 and No. 3 are
used to verify the accuracy of predicted cutting
forces. To this end, the fitted values of Kq and
Eq.(21) are adopted. The predicted and measured
cutting forces are given in Fig.4 for comparison.
Obviously, the predicted forces are in good agree-
ment with the measured ones both in magnitude and
in distribution for a wide range of cutting conditions,
regardless of cutting types. The detailed range needs
further experiments to identify. From Table 1, it can
be seen that the calibrated coefficients is valid with
the rotation speed from 2 000 r/min to 5 000 r/min.
Fig.4 Comparisons of measured cutting forces
and predicted ones.
Although K q (ϕ ) is calibrated only by one test
with a considerable saving of experiment costs, the
· 287 ·
proposed approach has a good prediction accuracy
in cutting force coefficients and the runout parame-
ters.
3 Conclusion
A new approach is developed to calibrate the
cutting force coefficients and the cutter radial
runout parameters in flat end milling. It is shown
that the total cutting forces have a closed form con-
sisting of a nominal component independent of
runout and a perturbation component depending
upon runout. This decomposition makes it possible
to identify the instantaneous cutting force coeffi-
cients with the nominal component. The cutter
runout parameters are then determined based on the
cutting force coefficients calibrated and the pertur-
bation component. The advantage is that the influ-
ence of the cutter runout that is unknown in advance
is eliminated in the calibration procedure of cutting
force coefficients. Finally, the proposed approach is
tested and validated by experimental results cover-
ing a wide range of cutting conditions.
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Biographies:
force and surface error prediction in flexible end milling systems.
WAN Min Born in 1979, male, Ph.D. student of North-
Transactions of the ASME Journal of Engineering for Industry
western Polytechnical University. The main research interest
1986; 108(4): 269-279.
includes milling simulation.
[12] Wan M, Zhang W H. Calculations of chip thickness and cutting
E-mail: m.wan@nwpu.edu.cn
forces in flexible end milling. International Journal of Advanced

Manufacturing Technology 2006; 29(7): 637-647. ZHANG Wei-hong Born in 1964, male, Ph.D., professor

[13] Wang J J, Liang S Y. Chip load kinematics in milling with radial of Northwestern Polytechnical University. The main research

cutter runout. Transactions of the ASME Journal of Engineering interests include structure analysis and optimization, cutting

for Industry 1996; 118(1): 111-116. simulation.

[14] Armarego E J A, Despande N P. Computerized predictive cutting E-mail: zhangwh@nwpu.edu.cn