Int J Adv Manuf Technol (1997) 14:160--171

I997 Springer-Verlag London Limited

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