Tamkang Journal of Science and Engineering, Vol. 3, No. 1, pp.

15-22 (2000)

15

Modeling of Cutting Forces in End Milling Operations

Wen-Hsiang Lai
Department of Mechanical Engineering University of Kansas Lawrence, KS 66045 E-mail: wenhsiang_lai@yahoo.com

Abstract
According to previous research of dynamic end milling models, the instantaneous dynamic radii on every cutting position affects the cutting forces directly since the simulated forces are proportional to the chip thickness, and the chip thickness is a function of dynamic radii and feedrate. With the concept of flute engagement introduced, it is important to discuss it with respect to radial and axial depths of cut because the length of the engaged flutes is affected by factors in the axial feed and rotational directions. Radial and axial depths of cut affect the contact area, which is the area that a cutter contacts with the workpiece. When radial and axial depths of cut increase, the cutting forces also increase since the engaged flute lengths are increased. Therefore, in order to have a clearer idea of the milling forces, the influences of dynamic radii, cutting feedrate, and radial and axial depths of cut are discussed in this paper.

Key Words: simulated forces, milling forces, dynamic radii, cutting

feedrate, flute engagement, radial and axial depths of cut, rake angle

1. Introduction
Milling operations are one of the most common machining operations in industry. It can be used for face finishing, edge finishing, material removal, etc. There are several parameters that influence the forces acting on the cutter. Because of these parameters, the forces may become unpredictable and result in larger dimensional variations when products are produced. In order to discuss these dimensional variations, several flexible simulation models have been introduced [1, 7, 10, 11, 14, 16, 17]. In these flexible models, simulated forces are proportional to the chip thickness Tc. The chip thickness refers to the thickness of material that each flute on a cutter removes at a certain position. The chip thickness is expressed as a function of dynamic radii and feedrate. Therefore, the dynamic radii and feedrate are key factors influencing simulated forces. With the concept of flute engagement introduced, it is

important to discuss it with respect to radial and axial depths of cut since the flute engagement is affected by factors in the axial feed and rotational directions. Flute engagement refers to the flutes on a cutter that are engaged at any instant in time as a milling operation is performed. The role of flute engagement in milling operations is important because it affects not only the cutting forces, but also the cutting surface. However, flute engagement is influenced by the radial and axial depths of cut because radial and axial depths of cut affect the width and length of the contact area in the axial feed and rotational directions, respectively. That is, the deeper the radial or axial depths of cut, the more flutes will be engaged, and thus increase the length of the engaged flutes. Figure 1 shows the geometry of the contact area. Figure 2 shows the flattened representation of a cutting tool. On the diagram, a horizontal and a vertical line are drawn from the lower left corner.

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Tamkang Journal of Science and Engineering, Vol. 3, No. 1 (2000)

The length of the horizontal line is CL, the circular length of the contact surface between the cutter and the workpiece, and AL is the distance between each flute in the axial direction. The length of the vertical line is equivalent to the axial depth of cut, a. This diagramming technique will be used later in the paper to describe the effects of radial and axial depths of cut. Another important influence on milling operations is the influence of rake angle. The concept of rake angle will be also discussed in this paper.
Cutting tool

2. Influences of Dynamic Radii

In a simulation model, the most significant influence on peripheral milling forces is the chip thickness. However, the chip thickness is mainly affected by dynamic radii, which are caused by cutter runout and tilt. In [17], Sutherland and DeVor indicate that the dynamic radii caused by cutter runout and tilt are:
RAD(i,k)=[RAD++2RADcos(--2(k-1)/Nf)+ (PL-Z[i])sin()+2(PL-Z[i])sin()(cos() 1/ 2 +RADcos(--2(k-1)/Nf-))] (1)

where
Contact area

Workpiece

Figure 1. The geometry of the contact area

Therefore, when 0, and cos(--2(k-1)/Nf )1 (or --2(k-1)/Nf 0 or ), equation (1) can be rewritten as:
RAD(i,k)=RAD+[+(PL-Z[i])sin()]cos(--2(k-1)/ Nf)
AL a CL

: cutter offset : locating angle for the end mill tilt : locating angle for cutter offset : measured angle : end mill tilt angle Z[i]: height above the free end of the cutter Nf : number of flutes PL : effective length of cut (i,j,k): flute engagement angle on the ith disk, jth angular position and kth flute

=> RAD(i,k) =RAD+ cos ( --2(k-1)/Nf) where

= + (PL - Z[i]) sin ()

(2) (3)

Figure 2. Flattened representation of cutting tool

According to equation (2), the dynamic radii for each flute are shown in Figure 3 within one revolution of the tool.

0.3765

Dynamic radius (inches)

0.376

0.3755

0.375

0.3745

0.374

0.3735 0 10 25 35 50 60 75 85 100 110 125 135 150 160 175 185 200 210 225 235 250 265 275 290 300 315 325 340

Degrees

(a) Tooth 1

350

Wen-Hsiang Lai: Modeling of Cutting Forces in End Milling Operations

17

0.3765

Dynamic radius (inches)

0.376 0.3755 0.375 0.3745 0.374 0.3735 0 10 25 35 50 60 75 85 100 110 125 140 150 165 175 190 200 215 225 240 255 265 280 290 305 315 330 340 355

Degrees

(b)Tooth 2
0.3765

Dynamic radius (inches)

0.376 0.3755 0.375 0.3745 0.374 0.3735 0 10 25 35 50 60 75 85 100 110 125 140 150 165 175 190 200 215 225 240 255 265 280 290 305 315 330 340 340
345

Degrees

(c) Tooth 3
0.3765

Dynamic radius (inches)

0.376 0.3755 0.375 0.3745 0.374 0.3735 0 10 25 35 50 60 75 85 100 110 125 140 150 165 175 190 200 215 225 240 255 265 280 290 305 315 330 355

Degrees

(d) Tooth 4
0.376 0.37575 0.3755 0.37525 0.375 0.37475 0.3745 0.37425 0.374 0 10 20 35 45 60 70 85 95 110 120 135 145 160 170 185 195 205 220 230 245 255 270 280 295 305 320 330 355

355

Dynamic radius (inches)

Degrees

(e) 4 flutes Figure 3. The dynamic flute radii within one revolution for a 4-flute, 3/8 inch diameter tool, i.e. Nf =4, RAD = 0.375 inch. One revolution refers to the angle () measured back as the flute engagement wraps up the helix angle.

From equation (2), it is obvious that dynamic radii are expressed as a function of the axial cutting length (Z[i]), instead of a function of the rotational angle. From another point of view, by considering the effect of cutter offset () and the measured angle (), the cutter radius is modified with respect to the position of engaged flutes and cutter offset; that is, the cutter radius varies at any

moment not only because of the flute position (caused by ), but also because of the cutter offset (caused by ). Figure 3 (e) shows the dynamic radii varying between RAD+ and RAD-. In addition, Figure 3 also shows that when flute 1 and flute 3 reach the maximum radii, flute 2 and flute 4 become the minimum radii respectively because the spacing angles between them equal 180.

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Tamkang Journal of Science and Engineering, Vol. 3, No. 1 (2000)

3. Influences of Feedrate
In order to assume the path that every flute cuts is a circle, it is necessary to assume the feedrate (f) is much smaller than the radius. However, if the cutting speed in the x-direction is low and the spindle speed (N) is high, ft (feed per flute) will become very small and fit the above assumption. In [8, 17], tangential forces (DFTAN), radial forces (DFRAN) and chip thickness are expressed as:
DFTAN = Kt Dz Tc DFRAN = Kr DFTAN Tc(i,j,k)=RAD(i,k)-RAD(i,k-m)+mftsin(i,j,k) (4) (5) (6)

60

Y Forces (lb)

50 40 30 20 10 0 1 324 647 970 1293 1616 1939 2262 2585 2908

Samples

(c) f = 3 (in/min.)
60

where m represents flute k is removing the material left by flute k-m (explained in [8]), Kt and Kr are the coefficients of tangential and radial force equations, and Dz is the chip thickness in axial direction. Therefore, it is obvious that Tc on the ith disk, jth angular position and kth flute is a function of dynamic radius RAD(i,k) and feedrate. When the feedrate is increased, the chip thickness is increased instantaneously as expressed by equation (7), and the tangential forces increase because the forces are proportional to the chip area (Dz Tc).
ft = f / (N Nf) (7)

Y Forces (lb)

50 40 30 20 10 0 1 329 657 985 1313 1641 1969 2297 2625 2953

Samples

(d) f = 4 (in/min.) Figure 4. Simulated forces with respect to four different feedrate (Nf = 4, RAD = 0.375)

4. Influences of Radial and Axial Depths of Cut

Flute engagement in the milling forces is important because it influences the forces directly. However, it is also influenced by the radial and axial depths of cut because radial and axial depths of cut affect the width and length of the contact area in the feed and rotational directions, respectively. That is, the deeper the radial or axial depths of cut, the more flutes will be engaged, and thus the lengths of the engaged flutes. 4.1 Radial depth of cut The radial depth of cut plays an important role in milling forces because as the radial depth of cut is increased, the contact area increases in the rotational direction, and the forces becomes larger. Figure 5 shows the effect of different radial depths of cut on the width of the contact area. When the radial depth of cut increases, the width of the contact area is increased, and thus increases the forces.

Figure 4 shows four different measured forces with respect to four different increasing feedrate. Each cycle on the graphs correspond to a single revolution of the tool. As the feedrate increases, the magnitude of the forces increase correspondingly. Also, the effect of dynamic radii increase with the feedrate as exhibited by higher force variations within a cycle.
60

Y Forces (lb)

50 40 30 20 10 0 1 269 537 805 1073 1341 1609 1877 2145 2413 2681 2949

Samples

(a) f = 1 (in/min.)
60

Y Forces (lb)

50 40 30 20 10 0 1 324 647 970 1293 1616 1939 2262 2585 2908

Samples

(b) f = 2 (in/min.)

Wen-Hsiang Lai: Modeling of Cutting Forces in End Milling Operations

19

cutter circular length

CL FSL

PL a

1111

1333

1555

1777

1999

2221

2443

2665

(a) Radial D.O.C. = 33%

CL cutter circular length FSL

Samples

PL a

(c) Radial D.O.C. = 66% Figure 6. Simulated forces with respect to different radial depths of cut (1 sample 0.2 degree)

(b) Radial D.O.C. = 50%

CL cutter circular length FSL

PL a

(c) Radial D.O.C. = 66% Figure 5. Representation of a cutting tool with respect to different radial D.O.C.

From Figure 6, it demonstrates that when the radial depth of cut increases, milling forces increase since the contact area is increased. In addition, it also shows that the shape of the measured force charts becomes smoother when radial D.O.C. increases. This is due to the flute engagement because when the radial D.O.C. is 50% or 100%, the engaged length is constant. This is because when one flute enters the workpiece, the preceding flute exits the workpiece simultaneously. 4.2 Axial depth of cut

50

40 30 20 10 0 1 314 627 940 1253 1566 1879 2192 2505 2818

Samples

(a) Radial D.O.C. = 33%

50 45 40 35 30 25 20 15 10 5 0

Axial depth of cut is another factor influencing the contact area since it affects the axial cutting length of the area. That is, when the axial depth of cut is increased, the length of engaged flutes increases, and the milling forces also increase. Figure 7 and 8 show that when the radial depth of cut is fixed (<50%), the effect of different axial depths of cut on the length of the contact area increases. When the axial depth of cut increases, the length of the contact area is increased, and thus the forces.
CL

Y forces(lb)

Y Forces (lb)

cutter circular length FSL

C PL AL
1 210 419 628 837 1046 1255 1464 1673 1882 2091 2300 2509 2718 2927

a A flute 4 flute 3 flute 2 flute 1

Samples

(b) Radial D.O.C. = 50% (a) a < C

2887

flute 4 flute 3 flute 2 flute 1

50 45 40 35 30 25 20 15 10 5 0

Y forces(lb)

223

445

667

889

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Tamkang Journal of Science and Engineering, Vol. 3, No. 1 (2000)

CL C AL A

cutter circular length FSL

PL

(b) a C Figure 7. Representation of a cutting tool with respect to different axial D.O.C.
30

positive. Figure 9 (a) shows the force analysis in x and y directions with the radial depth of cut much less than the radius (<< 50%). In this case, only one flute is engaged in the cut, and the y-forces are always in the positive y-direction and x-forces are in the negative x-direction. Figure 9 (b) shows the radial depth of cut larger than the radius (>50%). In this case, two flutes (more than one flute) are engaged in the cut, and the y-forces are also in the direction of positive y-direction, and x-forces are always kept in positive x-direction.
x (positive) y (positive) Ft (x) Fr (x) radial force tangential force Fr (y) + Ft (y)

Y Forces (lb)

25 20 15 10 5 0 1 299 597 895 1193 1491 1789 2087 2385 2683 2981

Samples

(a) a = 0.25 in.

30

(a) Radial depth of cut is less than 50%

Y Forces (lb)
25 20 15 10 5 0 1 296 591 886 1181 1476 1771 2066 2361 2656 2951

Fr (y)

radial force

flute 1 flute 2 Ft (y) tangential force

Fr (x) + Ft (x)

tangential force

Samples

radial force

(b) a = 0.5 in. Figure 8. Simulated forces with respect to different axial depths of cut

(b) Radial depth of cut is more than 50% Figure 9. The geometry of total forces in X and Y directions

From Figure 7, it should be noted that if the axial depth of cut is less than AL (a < C) and the radial depth of cut is fixed, when the axial depth of cut is deeper, the forces will be larger. On the other hand, if the axial depth of cut is larger than AL (a C), more flutes will be engaged and thus resulting in increased forces. FSL, CL, and AL can be expressed as:
FSL = 2 RAD / Nf
CL = RAD cos
1 (1

From another point of view, when the radial depth of cut is less than 50%, the total forces acting on the engaged tooth load the workpiece in the negative x-direction and positive y-direction. When the radial depth of cut is greater than 50%, the total forces load the workpiece in the positive x-direction and positive y-direction.

5. Rake angles
The formal definition of a rake angle is "the angle between the leading edge of a cutting tool and a perpendicular to the surface being cut". Figure 10 shows the picture of the rake angle. Rake angles come in two varieties, positive and negative. If the leading edge of the cutting tools is ahead of the perpendicular, the angle is, by definition, negative. On the contrary, if the leading edge of the cutting tools is behind the perpendicular, the angle is,

(8)
r/RAD)

where hx is the helix angle. When the values of cutting forces are measured (with positive x in direction of feed, and positive y into the material), x-forces are changed from negative values to positive values when the radial depth of cut is increased, while y-forces are always

AL = FSL / tan(hx)

(9) (10)

Wen-Hsiang Lai: Modeling of Cutting Forces in End Milling Operations

21

X Forces (lb)

by definition, positive. When a negative rake angle instrument is used, the material is cut by applying downward pressure which creates a compression wave ahead of the cutting tools. It's sort of like spreading butter on a toast or scraping paint with a plane cutting tools. It requires a lot of pressure to keep the cutting tools in contact with the surface being cut. This pressure and burnishing creates what is known as a smear layer, which consists of a layer of crushed dentin, necrotic debris and bacteria that gets burnished into the dentinal tubules and lateral canals. When a positive rake angle is used, on the other hand, the material is cut by separating one molecule of material from the work piece and creating a chip that curls away from the edge of the cutting tools. This cuts so readily that we have to make an effort to keep the cutting tools from digging into the workpiece. Compared to the negative rake angle, this is a very efficient way of cutting.

X Forces (lb)

-2 -4 -6 -8 -10 1 345 689 1033 1377 1721 2065 2409 2753

Samples

(a) Radial D.O.C.= 33%

2 1 0 -1 -2 -3 -4 -5 -6 1 348 695 1042 1389 1736 2083 2430 2777

X Forces (lb)

Samples

(b) Radial D.O.C.= 50%

10 8 6 4 2 0 1 346 691 1036 1381 1726 2071 2416 2761

Samples

(c) Radial D.O.C.= 66% Figure 11. Simulated X forces with respect to different radial depth of cut Figure 10. Rake angle

Acknowledgment
The authors gratefully acknowledge the support provided by the University of Kansas School of Engineering, Department of Mechanical Engineering, and Computer-Integrated Manufacturing Laboratory. This work was also partially supported by a grant from the National Institute of Standards and Technology.

6. Conclusion
In the simulation model, the most significant influence on the forces is the chip thickness (Tc). However, the dynamic radius caused by cutter runout and tilt is another key point to affect chip thickness. The effect of feed per flute on milling forces is apparent from Figure 4 (a), (b), (c), and (d). When feedrate is increased, the instantaneous chip thickness is increased, and forces are increased. Radial and axial depths of cut affect the width and length of the contact area, respectively. That is, when the radial and axial depth of cut are increased, the contact area is increased, and the forces become larger. From Figure 11, it is obvious that when radial depth of cut increases, the forces also increase. Furthermore, the measured X forces change from negative values to positive values when radial depth of cut is changed from 25% to 75%.

Reference
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Tamkang Journal of Science and Engineering, Vol. 3, No. 1 (2000)

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Manuscript Received: Oct. 08, 1999 Revision Received: Apr. 10, 2000 And Accepted: Apr. 21, 2000