A generalised model of milling forces

This paper presents the development of a generalised cutting force model for both end-milling and face-milling operations. The model specifies the interaction between workpiece and multiple cutter flutes by the convolution of cutting-edge geometry function with a train of impulses having the period equivalent to tooth spacing. Meanwhile, the effect of radial and axial depths of cut are represented by the modulation of the cutting-edge geometry function with a rectangular window function. This formulation leads to the development of an expression of end/face-milling forces in explicit terms of material properties, tool geometry, cutting parameters and process configuration. The explicitness of the resulting model provides a unique alternative to other studies in the literature commonly based on numerical integrations. The closed-form nature of the cutting force expression can facilitate the planning, optimisation, monitoring, and control of milling operations with complicated tool-work interactions. Experiments were performed over various cutting conditions and results are presented, in verification of the model fidelity, in both the angle and frequency domains.