Quantitative Evaluation of Cutting Resistance in the Finishing Process of End Milling.

This paper deals with the quantitative evaluation of cutting resistance in the finishing process of end milling to develop a computer-aided precision machining system which can control the surface profile error by varying the combination between the machine tool, tool specifications and cutting conditions. The cutting resistance generated under the finishing process of end milling is divided into cutting force, flank force and edge force through the measurement of total summed force and flank force. Also, A machining equation is developed to clarify the relation between cutting force and the removed chip area ; the flank force and contact area between the work surface and the flank face ; and the edge force and contact edge length. It is shown that the variation of cutting force, produced by the difference of work material and the progress of tool wear, can be evaluated through the specific cutting force and the force ratio between radial force and principal force. The same evaluation can be carried out on the flank force and the edge force in terms of the coefficient of friction and the specific edge force, respectively.