Prediction of effect of helix angle on cutting force coefficients for design of new tools

For accurate cutting force prediction in a milling process, material data for a given tool and workpiece, i.e. cutting force coefficients are required. Generally two methods, namely, orthogonal to oblique transformation or mechanistic method are used for calculation of cutting force coefficients. These methods have several drawbacks in designing of new milling tools. In order to help design of new tools, two methods are proposed to predict the effect of helix angle on cutting force coefficients. The methods were tested on five tools with different helix angles and predictions of the methods were compared with experiments.