Force Prediction Models For Helical End Milling... 2015

Int J Adv Manuf Technol
DOI 10.1007/s00170-015-8261-1
ORIGINAL ARTICLE
Force prediction models for helical end milling

of nickel-aluminium bronze
Ruihu Zhou 1 & Wenyu Yang 1 & Kun Yang 1
Received: 10 September 2015 / Accepted: 17 December 2015

# Springer-Verlag London 2016
Abstract Nickel-aluminium bronze is used widely in seawater environment. The mechanistic method and analytical
method to predict helical end milling force are briefly described and compared. The mechanistic approach is shown
to depend on milling force coefficients determined from milling tests. By contrast, the analytical method is based on a
predictive machining theory, which regards the workpiece
material properties, tool geometry, cutting conditions and
types of milling as the input data. Each cutting edge of the
helical end cutter is discretized into a series of infinitesimal
elements along the cutter axis and the cutting action of which
is equivalent to the classical oblique cutting process. Thus, the
cutting force components applied on each element can be
calculated using a predictive oblique cutting model and the
total instantaneous cutting forces are obtained by summing
up the forces contributed by all cutting edges. The equation
of equivalent plane angle is derivation through coordinate
transformation. Experiments on machining nickel-aluminium
bronze under different cutting conditions were conducted to
validate the proposed model.
Keywords Nickel-aluminium bronze . Helical end milling .

Analytical model . Mechanistic model
* Wenyu Yang
mewyang@mail.hust.edu.cn
State Key Laboratory of Digital Manufacturing Equipment and

Technology, School of Mechanical Science and Technology,
Huazhong University of Science and Technology, Wuhan 430074,
China
1 Introduction
Nickel-aluminium bronze (NAB) is a copper-based alloy
which is widely used for propulsion and seawater handling
systems in naval platforms, such as marine propellers, bearings [1]. However, the study of machinability of NAB in the
published literature is little. Maybe, the researchers consider
the machinability of NAB is well, compared with difficult-tomachine alloys.
The helical end milling is used extensively in manufacturing of surfaces, such as propellers, turbines, and dies/molds.
Modelling of cutting forces is the basis for prediction of machine tool chatter, tool wear and breakage, cutting parameters
optimization and surface quality [2]. There mainly exist three
methods to model milling forces: mechanistic, numerical and
analytical methods. The mechanistic models are commonly
available to predict cutting forces especially for new materials
and tools. Typical approach for numerical modelling is finite
element method (FEM). Currently available FE models can be
used to predict cutting forces, stress and temperature distributions. Simulations of FEM are time consuming and the physical meaning is not clear. Due to the fact that analytical
methods are more physics based rather than experimental
modelling, it can reflect the actual physical phenomenon better than the other methods. Arrazola et al. [3] summarized the
capabilities and limitations of modelling approaches.
Two types of mechanistic cutting force models are found in
the machining literature. In the first model, the effects of
shearing mechanism and effects of rubbing and ploughing
mechanisms are lumped into one specific force coefficient
for each cutting force component. In the second model, the
shearing and ploughing effects are characterized separately by
the respective specific cutting and edge force coefficients.
Budak et al. [4] described and compared the mechanistic and
unified mechanics of cutting approaches to the prediction of
milling forces. Gradiek et al. [5] developed expressions for

semi-empirical mechanistic identification of specific cutting
and edge force coefficients for a general end mill from milling
tests at an arbitrary radial immersion. Wan et al. [6] develop a
new approach able to identify the cutter radial run-out and
cutting force coefficients in the flat end milling. Recently,
Wan et al. [7] developed a new ternary-mechanism cutting
force model including chip removal, flank rubbing and bottom
cutting effects to predict cutting forces in flat end milling.
Wang et al. [8] used experiments to investigate the cutting
force coefficients in the average cutting force model.
For the analytical methods, the researchers try to establish
mathematical relations between the milling forces and several
mechanical aspects like friction, geometry and material behaviour. Oxley [9] developed a predictive machining theory that
allows for the high strain rate, high temperature and thermal
properties of the work material. Moufki et al. [10] developed
model of oblique cutting by introducing the
thermomechanical behaviour of the workpiece material and
the tool-chip interface friction characteristics. Li et al. [11]
presents an analytical method based on the unequal division
shear-zone model to study the machining predictive theory.
Through introducing the thermomechanical behaviour of the
workpiece material and tool-chip interface friction characteristics, Fontaine et al. [12], Moufki et al. [13], Li et al. [14] and
Fu et al. [15, 16] presented a analytical force model for end
milling process using the oblique cutting approach. Fontaine
et al. [12] present a predictive force model for ball end milling
based on thermomechanical modelling of oblique cutting.
Moufki et al. [13] developed an analytical thermomechanical
modelling of peripheral milling process using a predictive
machining theory. Li et al. [14] presented a theoretical modelling for cutting forces in helical end milling based on Oxleys
theory, where the action of a milling cutter was modelled as
the simultaneous actions of single-point cutting tools. Recently, Fu et al. [15, 16] also presented a predictive force model for
helical end milling and ball end milling process based on an
analytical thermomechanical modelling of oblique cutting.
Pang et al. [17] developed a modified Oxleys predictive machining theory to analyse the mechanics of cutting in end
milling using helical end mill tools.
However, some input parameters are based on assumptions which may induce error in analytical model. The
shear angle and friction coefficient are the important parameters which affect the accuracy of prediction of cutting
model. The main problem of finding a completely analytical way to determine shear angle and friction law has not
been solved. Hu [18] summarized the shear angle equations. Toropov et al. [19] developed a new equation for
the determination of the shear angle for continuous cutting assuming the curvilinear form of the shear line. Ozel
[20] comprised five friction models using FE simulations
of machining. Bahi et al. [21] developed a hybrid
analytical-numerical approach to determine friction

coefficient.
Generally, two approaches have been used to model
oblique cutting process. One of them is the normal plane
method [10]. Many researchers made the assumption that
analysis of oblique cutting in the normal plane is equivalent
to that of orthogonal cutting, and then all the velocity and
force vectors are projected on the normal plane. The other is
the equivalent plane method [14]. The equivalent plane is
determined by the cutting velocity and chip velocity; the
mechanism of oblique cutting is considered as the accumulation of a series of two-dimensional cutting processes. Li et al.
[14] developed the equivalent plane in oblique cutting; the
derivation of equivalent plane angle is brief which may be
difficult to understand. In this paper, the equivalent plane angle is obtained using another approach through coordinate
transformation.
The published papers use only one method to predict the
cutting force. It is the first time using both mechanistic model
and analytical model to obtain the milling force of NAB. For
simplicity, tool wear, tool run-out and deflection are not considered in this presented model. In order to evaluate the milling force coefficients, a set of milling experiments at different
feeds per tooth, spindle speed and radial cutting depth have to
be run. According to the fact that along an engaged cutting
edge of an end mill, the present paper proposes to apply the
thermomechanical model of oblique cutting developed by Li
et al. [14] to calculate the end milling forces. Orthogonal cutting theory based on unequal division shear zone is extended
to oblique cutting using equivalent plane approach.
The organization of this paper is as follows: After introducing the geometry of the cutter and the related parameters in
helical end milling process in Section 2, mechanistic model
and analytical model are developed in Sections 3 and 4. The
model validation is implemented and discussed in Section 5
by the end milling experimental data. Finally, conclusions of
this study are drawn in Section 6.
2 Geometry of the helix end milling

The geometric model of end milling and oblique cutting model are illustrated in Fig. 1. The related parameters are defined
in the global coordinates {o, X, Y, Z}. D is the cutter diameter,
i0 is the helix angle, ap is axial depth, dr is radial depth of cut
and N is the number of teeth.
For the point P on the jth cutting edge with elevation z, it is
located by the immersion angle j(z), which is determined by:
j z j1
2 2z
tani0
N D
where is the rotation angle of the reference cutting edge.

Z
Fig. 1 Geometry of helical end

mill and oblique cutting model
Vc
Rake
face
Milling cutter
Cutting edge
Chip
i0
Cutting
edge
t1
dz
ap
Workpiec
e
(b) Oblique cutting geometry
Workpiece
E-E Section
n
j 1
nr
j 1
j
(z)
zI dFr, j
j
r
Workpiece
zI
yI dFa, j dr
xI dFt , j
yI
dFt , j
Feed
(a) Geometry of helical end mill
The undeformed chip thickness h(j) varies periodically

with the immersion angle j(z) and is written as:

h j f t sin j i j
2
where ft is the feed per tooth. ij is a unit step function that
determines whether the teeth is in or out of cut,

1
f or st < j < ex
3
ij
0
f or j < st or j > ex
where the entrance angle st and the exit angle ex are defined
as:

.
8
< st 0; ex arccos 12d r D
up milling

.
: arccos 12d r D ; down milling
st
ex
4
The cutting action can be represented as the classical oblique
cutting processes with the inclination angle s equal to the
helix angle i0 [2], and the three differential cutting forces
(dFt, dFr, dFa) can be obtained from the oblique cutting model
as shown in Fig. 1c. In this model, the related parameters and
planes are defined in the local coordinates {P, xI, yI, zI}. Ps is
xI
dFr, j dFa, j
Ps
(c) Oblique cutting model
the cutting plane, Pn is the normal plane and n is the normal

rake angle measured in Pn and defined as:
n arctancosi0 tanr
where r is the radial rake angle (Fig. 1a). In addition, the

cutting velocity V = nrD, where nr is the spindle speed.
3 Mechanistic cutting force model

As shown in Fig. 1, the cutting force applied in element
P of the cutting edge j, whose elementary length is dz,
can be divided into three components: the tangential
force dFt,j(), the radial force dFr,j() and the axial
force dFa,j(). These can be calculated using:

8
< d F t; j j ; z K t h j dz
d F r; j j ; z K r h j dz

:
d F a; j j ; z K a h j dz
where Kt, Kr, Ka are the three cutting force coefficients.
The tangential, radial and axial forces can be expressed in

global coordinate system {o, X, Y, Z} as

3 2
d F x; j j ; z
cos j z sin j z

4 d F y; j j ; z 5 4 sin j z cos j z

0
0
d F z; j j ; z
For application to cutting forces modelling of helical

end milling, the cutting action of each infinitesimal element can be represented as the oblique cutting force. And
the relevant equations derived from the oblique cutting
model [14] are established and summarized. A set of coordinate systems are defined. These coordinate systems
are associated to the reference planes, and are summarized
as follows:
Coordinate system (xI, yI, zI); xI is parallel to the cutting
velocity direction, (yI, zI) is the reference plane Pr and (xI, yI)
is the cutting plane Ps.
Coordinate system (xc, yc, zc); zc is the rank cutting edge
direction, yc is parallel to yn, rank face plane A is determined
by yc and zc.
Coordinate system (xfl, yfl, zfl); zfl is chip flow direction and
xfl is collinear to xc.
Coordinate system (x, y, z); y is collinear to yn, (x, z) is the
normal plane Pn and z is perpendicular to the shear plane Psh.
Coordinate system (xs, ys, zs), xs is shear flow direction, zs
is collinear to z and shear plane Psh is determined by xs and ys.
Coordinate system (xe, ye, ze); xe is collinear to xs, ze is
parallel to zfl and equivalent plane Pe is determined by xe
and ze.
Equivalent plane is determined by cutting velocity and chip
velocity, Pe plane through xs and zfl. e is the equivalent plane
angle and calculated from coordinate system transformation.
(xe, ye, ze) is obtained by the rotation of angle e of the coordinate system (xs, ys, zs) around the xe axis.

3
32
d F t; j j ; z
0

0 54 d F r; j j ; z 5
1
d F a; j j ; z
7
The average cutting force calculated as follows:
3
2 32
Fx
Kt
cos2
2sin2
N
a
f
6 7
p t 4
cos2
K r 54 2sin2
4 Fy 5
8
0
0
K
a
Fz
2
3ex
0
0 5
4cos
st
8
Given the cutter geometry and immersion conditions, only
the specific cutting force coefficient remain unknown in the
right-hand side of Eq. (8). The coefficients can therefore be
determined by equating the measured cutting forces with the
corresponding expressions. The details can be found in Wan
et al. [6].
4 Analytical cutting force model

In Figs. 1 and 2, geometric parameters associated to oblique
machining are illustrated. The normal shear angle, normal
rake angle, the undeformed chip thickness and the width of
cut are given respectively by n, n, t1 and w. In the tool rake
face, the chip flow direction is defined by the chip flow angle
c. s is shear flow angle.
8 9 0
1
< xe =
ye @ 0
: ;
ze
0
0
cose
sine
18 9
0
< xs =
sine A ys
: ;
cose
zs
Fig. 2 Oblique cutting model

and chip formation of
infinitesimal cutting edge
n zc
z fl A
Vc
zn
Pr
xn
Vc
yn
Pe
yI
zI
xs
P
Psh
sh
x
xI
Vs
Vn
chip
t2
dFt , j
w
dFr , j dFa , j
Ps
Ps
yn
yI
zI = zn
xI
Pn
zn n
xn
yc = y n
zc c z
fl
zc
xn
xc
yc
zc = z fl
(a) Geometrical parameters associated to oblique machining
h E
A
Vc
tool
ze
xe
t1
D B (o)
workpieces
(b) Non-equidistant shear model
ze sine ys cose zs
10
(xs, ys, zs) is obtained by the rotation of angle s of the coordinate system (x, y, z) around the z axis.
8 9 0
18 9
coss sins 0 < x =
< xs =
11
@ sins coss 0 A y
y
: ;
: s;
z
0
0
1
zs
(xc, yc, zc) is obtained by the rotation of angle (n n) of the
coordinate system (x, y, z) around the y axis.
8 9 0
18 9
cosn n 0 sinn n < x =
< xc =
A y
@
12
y
0
1
0
: c;
: ;
zc
sinn n 0 cosn n
z
(xfl, yfl, zfl) is obtained by the rotation of angle c of the coordinate system (xc, yc, zc) around the xc axis.
8 9 0
18 9
1
0
0
< xfl =
< xc =
yfl @ 0 cosc sinc A yc
13
: ;
: ;
zfl
0 sinc cosc
zc
From Eqs. (11), (12) and (13), zfl is calculated as:
zfl cosc sinn n coss sinc sins xs
cosc sinn n sins sinc coss ys
cosc cosn n zs
14
Since ze is parallel to zfl, from Eqs. (10) and (14), equivalent plane angle e can be obtained as:
cosc sinn n tans sinc coss
cosc cosn n
sinn n sins tanc coss
cosn n
Also, e can obtained from Li et al. [14]. The shear slow

angle s which characterizes the shear direction in primary
shear zone are given by Moufki et al. [10].
tans
tans cosn n tanc sinn

cosn
16
The chip flow angle c on the rake face A is given with the
assumption that the friction force and the chip flow direction
are collinear and can be calculated from the following equation [10]:
cosn n sinn sinc tans cos2 n n cosc
cosn sinn n sinn tansinc cosc
tantans sinn n cosn n cos2 c 0
17
In Fig. 2b, the primary shear zone is modelled as a parallel

and non-equidistant shear band of thickness h which consists
of two non-equidistant thickness 1h and h, 0; 1. In the
hodograph, V, Vc, Vn and Vs are denoted as the cutting velocity,
the chip velocity, the normal velocity and the shear velocity,
respectively.
For this shear zone, the corresponding physical values are
detailed in Li et al. [11], which are given as follows:
8
:m
q
>
ze 1h; 0
<
q ze 1 h
1
h
:
:
18
>
: m q hze q
ze 0; h
h
tane
15
8
>
>
>
<
:
m cose
ze 1hq1
ze 1 h; 0
V coss sinn q 11 hq
ze
:
:
>
>
m cose
cose hm
q1
>
:
ze 0; h
q hze
V coss sinn q 1h
V coss sinn q 1
q 1V s q 1V coss cosn
:
m
h
hcoss cosn n
20
cosn cosn n coss cosn coss tans sins

21
cosn
Vc
V coss sinn
V coss cosn
; Vs
cosc cosn n
coss cosn n
22
: :
where ; m ; and represent the shear strain rate, the maximum shear strain rate and the shear strain. In this paper,
h = 0.025 mm, q = 3.
19
The workpiece material is supposed to be isotropic and

viscoplastic-rigid, and its behaviour is described by the
Johnson-Cook constitutive model:
!#

n "
:
T T r m
1 Cln
s p A B p
1
T m T r
3
3
:0
23
:
where s ; ; and T represent the shear stress, the shear strain,
the shear strain rate and the absolute temperature, respectively.
The material characteristics are defined by the parameters A,
B, C, n, m, which stand for the yield strength, the strength coefficient, the strain rate constant, the strain hardening exponent and the thermal softening coefficient, respectively.
In cutting process, the boundary of the primary shear zone
can be considered adiabatic; the thermal conductivity is then
negligible. Assuming that a fraction (Taylor-Quinney
coefficient) of the plastic work is converted into heat, since
the temperature depends only on the coordinate ze under the
steady flow condition, consequently, the heat transfer equation
becomes:
dT
cose
:
dze cV sinn coss
dN s
tann n tancosc coss

d Fs
1tancosc tann n
28
Therefore, for the infinitesimal element of the jth cutting edge, the three differential cutting force components
dF t,j , dF r,j , dF a,j (tangential, radial, axial), applied to
point P in Fig. 2a, are evaluated from the following
matrix form:
9 2
8
coss cosn cossh sins sinsh
< d F t; j =
d F r; j 4
sinn cossh
;
:
d F a; j
sins cosn cossh coss sinsh
3

coss sinn
d Fs
cosn 5
dN s
sins sinn
24
29
where , c and represent the material density, the special

heat and the Taylor-Quinney coefficient. In this paper,
= 0.85 [16].
Normal shear angle n is given by the Li et al. [14]:
The cutting forces in x, y and z directions at the small

differential elements may also be transformed as the following:
n

2
4 2
25
As suggest by Dudzinski et al. [22], the mean friction coefficient may be a power function of the chip velocity:
f f 0V c
26
In this paper, f0 = 0.704, p = 0.248.

The shear angle is an important parameter in analytical
cutting force model. Table 1 summarized the shear angle
equations.
Furthermore, the shear force dFs, which is proportional to
the shear stress s, along with the normal force dNs can be
expressed as:
d Fs
s t 1
dz
coss sinn
27

3 2
d F x; j j ; z
cos j z

4 d F y; j j ; z 5 4 sin j z

0
d F z; j j ; z
2

3
32
d F t; j j ; z
sin j z 0

cos j z 0 54 d F r; j j ; z 5
0
1
d F a; j j ; z
30
By integrating Eq. (30), respectively, the total cutting force
in each direction can be obtained. The algorithm for predicting
the cutting forces in end milling is shown in Fig. 3.
Fm
N Z
X
j1
z2
d F m; j dz;
m x; y; z
31
z1
where z1, z2 are the lower and upper axial engagement limits of
the in-cut portion.
5 Model validation
5.1 Experiment details
Table 1
Summary of shear angle relationship
Researchers
Relationship
Krystoff (1939) [18]

Mechant (1945) [18]
Lee, Shaffer (1951) [18]
Hucks (1951) [18]
Shaw (1953) [18]
Weisz (1957) [18]
Wright (1982) [18]
= /4 +
= /4 + /2 /2
= /4 + + (s/s 1)/2
= + (CM arctan 2)/2 + arctan
= + arctan(s/s)
= + 54.7

cos1 s cos 4 2 sin 4 2
A Toropov (2007) [19]
= /4 f + 5/8
To validate the proposed modelling of end milling, a series of

helical end milling tests have been performed on a vertical 5axis machining center (Tuopu VMC-C50) with dry cutting
and experimental setup is shown as in Fig. 4. The workpiece
is mounted on a three-component Kistler table dynamometer
(9257B) which is used to measure cutting forces. The sampling frequency is 25 kHz and sampling time is 10 s for each
test. The carbide cutter is Sandvik Coromant R215.34C
12040-DC26K 1640, which has four-flute cutting edge, 40
helix angle, 12 rake angle and 12 mm diameter. The composition of nickel-aluminium bronze (NAB) has the following
chemical composition:
Cu 85%; Al 8:510%; Fe 4:05:0%; Ni 4:05:0%;
Others 0:1%:

Fig. 3 The flow chart of cutting
forces calculation
Input parameters
Work piece material:A B C n m
Helical end geometry:D Ni0
Cuttingconditions: nr , ap , ae , f
Determine number of angular integration steps
L,number of axial integration steps K,entry
angle exit angle
Initialize force variation registers

Angular integration loop: i=1 to L
Initialize the instantaneous force integration
registers
Calculate the tool rotation angle
Tooth integration loop:j=1 to N
Calculate the immersion angle ofthe jth flute
bottom angle
Axial integration loop:s= 1 to K
Oblique cutting model of

infinitesimal cutting edge
Calculate the shear flow angle,chip flow angle
and equivalent plane
s=s+1
Calculate the immersion angle of the sth discrete
point (height z)on the jth edge from Eq.(1)
Is the cutting
region or not?
Calculate the chip thickness ,Normal rake angle,

friction angle,shear angle,cutting velocity,width
of cut
Calculate the temperature distribution in the

primary shear zone
Calculate the shear flow stress,shear and
normal forces
Calculate tangential,radial and axial force
Calculation the force components(dFx,dFy,dFz)

From Eq.(30)
j=j+1
K>s
N>j
Y
Sum the force of aallengagededges
i=i+1
L>i
Y
Output the cutting force variation with tool
rotation angle
In previous work [16], the flow behaviour of material NAB

is described by the modified Johnson-Cook constitutive law
and its involved parameters are given as:
A295 MPa; B759:5 MPa; C 0:011; n0:405; m1:09;
:
0 0:001 1=s; T m 1311 K; T r 293 K
The other material parameters are given by:

7530 kg=m3 ; c419:0 J=kgKk 41:9 W=mK:
where is density, c is specific heat and k is thermal

conductivity.
Thirteen milling tests are conducted with different cutting
conditions, each test repeated three times. The instantaneous
milling forces for one revolution of the cutter can be obtained
by taking the average values of the cutting forces measures in
the neighboring ten periods. Fx, Fy, Fz represent forces in the
feed, normal to the feed, and axis directions, respectively. The
workpiece size is 100 100 10 mm. The cutting conditions
for the test are shown in Table 2. All the cutting is down

Fig. 4 Milling cutting test
milling and axial depth of cut is 1.5 mm. The program of

cutting force simulations was all executed with Matlab2010b
on a computer.
5.2 Mechanistic model results
The cutting forces measured in tests 19 are used to determine
the cutting force coefficients. Based on the mechanistic model, calibrated values of Kt, Kr, Ka are shown in Table 3. The
average cutting force coefficients are:
K t 1494 N=mm2 ; K r 1444 N=mm2 ; K a 105 N=mm2 :
The results of comparison are shown in Fig. 5ad. Although
cutting parameters, such as spindle speed, feed per tooth and
radial width of cut, are different, mechanistic forces match
well experimental ones in both shape and magnitude for all
cutting tests, while slight errors exist and are tolerable. Due to
noisy signals such as uncertain factors of the piezoelectric
Table 2
Cutting conditions for helical end milling, down milling
Test no
Spindle speed
(rpm)
Feed per tooth

(mm/tooth)
Radial depth
of cut (mm)
1
2
3
4
5
6
7
1000
1000
1000
1600
1600
1600
2000
0.04
0.05
0.06
0.04
0.05
0.06
0.04
6
6
6
6
6
6
6
8
9
10
11
12
13
2000
2000
2000
2000
1800
1600
0.05
0.06
0.04
0.05
0.05
0.03
6
6
4
4
6
6
dynamometer or the tiny foundation vibrations of nearby machines in the experimental environment, slight perturbations
of measured cutting forces exist when the magnitudes of cutting force components attain a relatively low level. Even in
this condition, the trends of simulation and experimental data
are in good agreement. In Fig. 5a, since the experimental data
has run-out, the magnitude of cutting force did not match well,
but the shape of force profile during the cutter revolution is
captured well.
5.3 Analytical model results

In the simulations, the cutter was discretized into 15 disks
(calculation increments dz = 0.1 mm); the force calculations
were performed every 1 of cutter rotation (calculation increments d = 1).
Figure 6 shows that under these cutting conditions, the
experimental values of milling force have a good agreement
with the proposed analytical model on the waveform, amplitude and phase. Each of the plots captures the cutting forces
for one revolution. There is a small amount of amplitude discrepancy between the predictions and the experiments. The
main reasons for this deviation may be attributed to the following: (1) the cutter deflection is caused by the peak forces
due to the stiffness in actual helical end milling process. In
addition, the plough forces are introduced at the toolworkpiece interface zone due to the little flank wear of the
cutter. (2) In the proposed model, the predicted results are
influenced due to the errors caused by some measured or
identified parameters. (3) There is another factor which is
Table 3
Cutting force coefficients (units KtKrKa = [N/mm2])
Test no. 1
Kt
Kr
Ka
1321 1612 1743 1004 1339 1819 1648 1420 1543

1010 1640 1566 1086 1496 1436 1610 1640 1519
105 125
90
43
54
98
154
61
217

250
Fig. 5 Comparisons of
mechanistic model and
experimental results
250
Mechanistic
Mechanistic
Experiment
200
Cutting Forces(N)
Cutting Forces(N)
Fy
150
100
50
0
Fz
-50
-100
45
90
100
50
0
Fz
Fx
-50
Fx
0
Fy
150
135
180
225
270
315
-100
360
45
90
Tool rotation angle (deg)
135
225
270
315
360
(b) Test 8
250
250
Mechanistic
Mechanistic
Experiment
Experiment
200
200
Fy
150
Cutting Forces(N)
Cutting Forces(N)
180
(a)Test 2
100
Fx
50
0
Fz
Fy
150
100
50
0
Fz
Fx
-50
-50
-100
Experiment
200
-100
0
45
90
135
180
225
270

(c) Test 11
difficult to avoid: the tool run-out. In milling, this geometrical

default is mainly due to the offset between the position
of the tool rotation axis and the spindle rotation axis
(Fontaine et al. [12]). The consequence is a tool rotation
around the spindle axis with an eccentricity. This eccentricity modifies the tool engagement and the local cutting conditions (cutting velocity and angles). Then, the
run-out has a direct effect on the cutting forces level
and variation. Its effect is particularly significant when
the undeformed chip thickness reaches small values, as
shown in Fig. 6h.
Influence of cutting parameters on cutting force:
315
360
45
90
135
180
225
270
315
360

(d) Test 12
cutting forces decrease with the cutter-workpiece

engagement domain expansion.
(3) Spindle speed nr. Comparing the predicted force components in Fig. 6b, e, the global level of cutting forces
decreases theoretically with increasing values of spindle
speed, which is accounted by Eqs. (26). Actual observations show obvious changes in measured force Fx but
little changes in Fy (see Fig. 6b, e). In fact, the cutting
force is greatly influenced by tool run-out when the spindle speed increase.
5.4 Comparison of two models

(1) Feed per teeth ft. It can be noted that the feed rate variation affects directly the cutting forces; indeed, these
values depend proportionally on the undeformed chip
thickness. Figure 6h, d shows the three force components
maximum values double closely as the feed per teeth
increases from 0.03 mm/tooth to 0.06 mm/tooth. In milling parameters, ft has the greatest effect on cutting force.
(2) Radial depth of cut dr which influences the cutting
force by changing the immersion angles of entrance
and exit. Figure 6e, f shows the cutting forces for
the various immersion angles of exit. When cutting
width decreases from 6 to 4 mm, the immersion
angles of entrance change from 90 to 138. So,
Figure 7a, b is a comparison of mechanistic and analytical model result in cutting conditions for test 2 and test
8. It is shown that the proposed analytical method
closely agrees with mechanistic method results. The
mechanistic method requires a set of cutting tests for
each milling cutter conditions, whereas the analytical
method requires input data and using oblique cutting
model extend to end milling. The mechanistic model
is used widely on new materials or the materials properties not given. This method can be used in industry
since it calibrates cutting force coefficients efficiently.
The analytic model has a clear physical meaning, but

250
250
200
Cutting Forces (N)
Cutting Forces (N)
200
Fy
150
100
50
0
Fy
150
100
50
0
Fz
Fz
-50
Fx
-50
Fx
-100
-100
0
45
90
135
180
225
270
315
360
45
90

(a) Test 1
Cutting Forces (N)
Cutting Forces (N)
315
360
Analytical
Experiment
100
50
50
-50
-50
-100
0
45
90
135
180
225
270
315
360
45
90
135
180
225
270
315
360

(d) Test 6

(c) Test 5
250
250
Analytical
Experiment
Analytical
200
Experiment
Cutting Forces (N)
200
Fy
150
Cutting Forces (N)
270
150
100
150
100
50
0
50
45
90
135
Fx
Fx
0
Fy
100
Fz
-50
Fz
-50
180
225
270
315
360
1
- 00
45

(e) Test 8
250
90
135 180 225 270
(f) Test 11
315
360
250
Analytical
Analytical
Experiment
200
200
150
150
Cutting Forces (N)
Cutting Forces (N)
225
200
150
50
0
50
0
Fz
Fx
-50
-50
45
90
135
180
225
270
315
360
Toolrotation angle (deg)

(g) Test12
Fig. 6 Comparison of proposed analytical model and experimental results
Experiment
Fy
100
100
-100
180
250
Analytical
Experiment
200
-100
135

(b)Test 2
250
-100
Experiment
Analytical
Experiment
Analytical
-100
45
90
135
180
225
270

(h) Test 13
315
360

250
Fig. 7 Comparison of analytical

model, mechanistic model and
experimental results
250
Prediction(Analytical)
Experiment
Prediction(Mechanistic)
200
Fy
Cutting Forces (N)
Cutting Forces (N)
Fy
150
100
50
0
Fz
Fx
-50
150
100
50
0
Fz
Fx
-50
-100
Prediction(Analytical)
Experiment
Prediction(Mechanistic)
200
-100
0
45
90
135
180
225
270
315
360
1.
2.
4.
However, the effect of tool run-out and deflection in milling process need to be considered in future work for more
accurate prediction of milling forces.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Acknowledgments This work is supported by the National Key Basic

Research Program (NKBRP) of China (No. 2014CB046704), Key Projects in the National Science & Technology Pillar Program of China (No.
2014BAB13B01).
135
180
225
270
315
360
References
6 Conclusion
(1) Mechanistic modelling is an experimental approach

where the cutting force coefficients are calibrated for a
given milling tool and workpiece pair at different radial
depth of cut, feed per tooth and spindle speed.
(2) An analytical model incorporates cutting force and thermal models derived for oblique cutting conditions considering geometric transformations as well as location
effects. A new approach is used to get the equivalent
plane angle through coordinate transformation.
(3) The mechanistic model and analytical model results for
cutting forces are in good agreement with the experimental approach. The combined use of analytical models and
mechanical models can improve prediction accuracy, especially for new materials or the material property is little
in published papers.
90
(b) Test 8
3.
In this paper, the mechanistic model and analytical model are

proposed and compared with experiment result. The contributions of proposed model are drawn as follows:
45
(a) Test 2
some parameters are still uncertain such as shear angle

and friction coefficient which attracts many researchers
to study. The analytical force models present major advantages and may dominate in future advances of metal
cutting modelling reviewed by Arrazola et al. [3].
14.
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