Generalized cutting force model in multi-axis milling using a new engagement boundary determination approach

Official URL: http://dx.doi.org/10.1007/s00170-014-6453-8

Simulation of cutting processes provides valuable insight into machining applications which have complex mechanics. In this paper, a generalized cutting force model is proposed for multi-axis milling operations. In the proposed model, the cutting tool envelope is defined either as revolution of a multi-segmented curve or using seven-parameter milling tool definition. The engagement between the cutting tool envelope and workpiece is calculated using a new, robust, and fast approach based on projective geometry. Exact chip thickness expression is used to simulate cutting kinematics for all types of edge geometries, such as serrated, variable pitch, and variable helix cutting flutes. The performance of the method proposed for determination of engagement boundaries is discussed through calculation time studies under several conditions. The predictions are verified and discussed through cutting experiments, conducted at multi-axis machining conditions using various cutting tool geometries.