Milling Force Modeling: A Comparison of Two Approaches

This paper evaluates the dependence of cutting force coefficients on milling process parameters including feed per tooth, spindle speed, and radial immersion. Two methods are described for determining the cutting force coefficients: 1) the average force, linear regression method; and 2) the instantaneous force, nonlinear optimization method. A series of test cuts were performed and the cutting force coefficients calculated using the two methods are compared. Milling stability experiments were then conducted to validate the calculated cutting force coefficients. It was found that feed per tooth, spindle speed, and radial immersion exhibit a nonlinear relationship with the cutting force coefficients.