A Mechanistic Cutting Force Model for New Barrel End Mills

The complexity and increasing demand of turbomachinery components manufactured for the aerospace sector has led these parts to become reference of the research and development of 5-axis machining. We can highlight as key components the Integral Bladed Rotors (IBR), such as impeller and blisk. Due to its functional and technical requirements, these parts are formed by complex geometry and manufactured in difficult to cut materials. Despite recent advances in five-axis machining, the reliable and efficient manufacturing of these components is still a challenge. Conventional pure geometric analyses carried out by CAM systems are insufficient in a machining process with high mechanical stresses. Tool deflections and/or vibrations in finish operations can produce damages in piece or machining components. In the present work a cutting force model for barrel-shaped cutter is proposed in order to optimize toolpath design process.