Numerical simulation and prediction of cutting forces in five-axis milling processes with cutter run-out

Radial cutter runout is a common issue in milling processes and has a direct effect on milling stability due to variations of resulting chip load and forces. This paper presents a new method to effectively model and predict the instantaneous cutting forces in 5-axis milling processes with radial cutter runout based on tool motion analysis. First, the undeformed chip thickness model taking runout effect into account is established under continuous change of cutter axis orientation by means of the sweep traces of cutter edges. Second, the engaged cutting edge is determined and cutting coefficients are subsequently calibrated. Finally, the method of identifying runout parameters from the measured cutting forces is proposed, and mechanistic method is then applied to predict the cutting force. Since this method is completely based on the relative motion analysis of tool-part, it can reduce the prediction errors of cutting forces effectively and is suitable for generic rotation cutters. Several validation examples are given under different cutting conditions to prove its effectiveness and accuracy. The results reveal that the developed method can predict the cutter forces with a high accuracy and has the ability to be used in simulations and optimizations of five-axis machining.

► Approach for predicting cutting forces in five-axis milling process with cutter runout.
► Modeling of undeformed chip thickness by means of the true sweep traces of cutter edges.
► Determination procedures of cutting edge points and cutter runout parameters.
► A series of milling experiments under varying machining conditions.
► Good agreement between predicted and measured cutting forces.