High-adaptable prediction method of flat-end milling force based on material properties for difficult-to-machine materials

Flat-end milling is an important processing method that has been widely used for complex parts machining in aerospace, biomedical and automotive industries. As the milling force is an important physical parameter to comprehensively reflect the milling process, its prediction is of great significance. However, most of the proposed cutting force prediction methods is applicable only to a fixed tool-material couple, the change of workpiece material will lead to the inapplicability of the model, and a completely new one has to be rebuilt from the beginning. As the high-speed milling shows obvious superiority in difficult-to-machine material machining and based on the differential and oblique cutting mechanisms, a high-adaptable method to predict the flat-end milling force is proposed in this study for difficult-to-machine materials in high-speed milling. The emphasis of this method is on the involvement of the workpiece material properties and the machining conditions as input elements with the combination of mechanistic approach and unified mechanics of cutting approach. Finally, the comparison between the predicted result and the experimental result confirms the effectiveness of the presented flat-end milling prediction method for different difficult-to-machine materials in high-speed milling based on the straight-line flank milling and the curve-line flank milling.

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