Computerized Predictive Cutting Models for Forces in End-Milling Including Eccentricity Effects

The work presented is part of an ongoing research programme aimed at developing computer based predictive models for machining performance characteristics of practical operations using a mechanics of cutting approach. In this paper a software module for end-milling forces, torque and power is developed and experimentally tested for addition to the previously reported CAD/CAH software which included turning, drilling and peripheral milling modules. The cutting model presented allows for the many salient process variables as well as the inevitable eccentricity (run-out) found in practice. The predicted and experimental results have shown good correlation and highlighted the importance of eccentricity on the forces and their fluctuations. The practical implication of the model and test rig are briefly discussed and shown to provide a novel means of improving milling cutter designs.