Time-averaged and Instantaneous Mechanistic Models using Artificial Force Synthesis in Helical End Milling

This paper aims to develop field-deployable mechanistic milling models with the aid of the Virtual Machining Simulation Environment (VMSE). Stabler's rule and sharp tool hypotheses were adopted. VMSE force components for artificial materials with unit normal (Kn) and friction (Kf) force coefficients were least-squares-fit to experimental values to obtain actual Kn and Kf and then functionally fit to chip thickness h, speed v and normal rake angle α. The new approach was tested with a simple ball end mill tool. Both time-averaged (MMa model) and location-averaged instantaneous (MMi model) force components from a subset of experimental data were used. Physical force components reported by the VMSE with both MMa and MMi for the complete test matrix agreed with their experimental counterparts. MMi significantly expanded the range of h and was identical to MMa in the common range.