FORCE PREDICTION MODELS AND CAD-CAM SOFTWARE FOR HELICAL TOOTH MILLING PROCESSES .1. BASIC APPROACH AND CUTTING ANALYSES

The need for reliable quantitative machining performance information for efficient and effective use of machining operations is discussed, as are the recent developments of predictive models and modular software for forces and power in practical operations based on a unified mechanics of cutting approach. The cutting action, comprehensive predictive force models and software modules for peripheral milling, end-milling and slotting operations are developed at three levels of sophistication. The first and basic or 'ideal case' model assumes perfectly rigid cutters with no eccentricity and includes all the important process variables, while the second or 'eccentricity' model also includes the inevitable eccentricity noted in practice. The third and most sophisticated 'deflection' model incorporates both eccentricity and cutter deflection in addition to the many process variables. The necessity to individually study each type of milling operation in order to identify, assess and verify the appropriate predictive model is highlighted in this first paper and the findings for each operation are reported in subsequent parts of this investigation.