Cutting forces modeling for end milling of curved surfaces

An analytical model of cutting forces was established in end milling of curved geometries During the cutting process where the curvature of the workpiece geometry varies, cutting parameters such as the instantaneous undeformed chip thickness, the federate, entry and exit angles too vary along the tool path. Taken the curved geometries into account, the cutting process was discretized into a series of steady-state cutting process at intervals of the feed per tooth. Based on the steady-state cutting process, the mathematical expressions for the federate, entry and exit angles were obtained and Fourier series expansion was utilized to derived the cutting forces model. A PCrNi3MoVA component with curved geometry was machined. Compared with the experimental results, validity of the cutting force model was demonstrated.