Analytical model of milling forces based on time-variant sculptured shear surface

• The sculptured shear surface in the milling processes was proposed.
• The analytical model of milling forces based on sculptured shear surface is build.
• The statistic models of shear angle, friction angle and shear stress were built.
• The milling experiments validated the accuracy of proposed milling forces model.
• The effect of cutting tool geometrical parameters on milling forces is analyzed.
• The effect of milling parameters on milling forces is analyzed.

A concept of sculptured shear surface was proposed in this study. The sculptured shear surface is determined by helix structure and movement of milling tool. The area of sculptured shear surface is time variant during milling processes. The projected area of sculptured shear surface in three directions determines the milling forces in three directions respectively. The analytical model of milling forces based on sculptured shear surface is build and this analytical model is verified by the milling experiments. Finally the effect of cutting tool geometrical parameters (helix angle and rake angle) and milling parameters (axial depth of cut, radial depth of cut, feed rate per tooth) on milling forces is analyzed by proposed milling force model.

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