Improved dynamic cutting force model in peripheral milling - Part 2: experimental verification and prediction

Cutting trials reveal that a measure of cutter run-out is always unavoidable in peripheral milling. This paper improves and extends the dynamic cutting force model of peripheral milling based on the theoretical analytical model presented in Part I [1], by taking into account the influence of the cutter run-out on the undeformed chip thickness. A set of slot milling tests with a single-fluted helical end-mill was carried out at different feed rates, while the 3D cutting force coefficients were calibrated using the averaged cutting forces. The measured and predicted cutting forces were compared using the experimentally identified force coefficients. The results indicate that the model provides a good prediction when the feed rate is limited to a specified interval, and the recorded cutting force curves give a different trend compared to other published results [8]. Subsequently, a series of peripheral milling tests with different helical end-mill were performed at different cutting parameters to validate the proposed dynamic cutting force model, and the cutting conditions were simulated and compared with the experimental results. The result demonstrates that only when the vibration between the cutter and workpiece is faint, the predicted and measured cutting forces are in good agreement.