Fourier analysis for micro-end-milling mechanics

This paper presents the work of establishing a Fourier series expression for the cutting force with shearing and plowing mechanisms in micro-end-milling as an explicit function of cutting parameters and tool/workpiece geometry. Based on the Fourier chip thickness model considering trochoidal nature of tool trajectories, the proposed cutting force model provides an expression of Fourier series via convolution approach. Fourier series coefficients of the cutting forces are shown to be explicit algebraic functions of various tool parameters and cutting conditions. Due to the closed-form nature of expressions for cutting force, four global cutting constants which are associated with shearing and plowing mechanisms are identified by measured cutting force without any iterative algorithm or best-fit method. Experiments verify the effectiveness of the proposed cutting force model and show that cutting force due to plowing mechanism plays an important role in micro-end-milling process.

► The proposed cutting force model provides an explicit expression in Fourier series.
► The cutting force is analyzed as a linear function of chip load with shearing force and plowing force.
► This study applies the Fourier chip thickness model to identify cutting parameters in micro-end-milling.
► The cutting force model provides an efficient method for predicting the cutting force in micro-end milling.