### Modeling of high speed milling forces based on kinematics: comprehensive modeling and experimental study

• Received:2022-04-08 Revised:2022-06-21 Online:2022-09-22 Published:2022-09-22

Abstract: Abstract：The milling force is one of the most important process parameters in milling process. Accurate feedback of milling force information is very important to ensure the stability and precision of milling process. However, there are many factors that affect the milling force, and there is currently a lack of a comprehensive milling force model that consid-ers multiple factors. Therefore, this article focuses on research and comprehensively considers the influence of tool wear, tool run-out, and tool elastic deformation on the instantaneous undeformed cutting thickness. At the same time, it analyzes the relationship between elastic deformation and variety of entry and exit angles for each engaged flute, and the instanta-neous cutting thickness model is improved. Based on kinematic analysis, the position of cutting edge is unified with the shape of premachined workpiece, and a comprehensive model of high speed milling force is established. In order to verify the accuracy and generality of the proposed model, a series of milling experiments under different parameters are carried out. The experimental results show that the predicted value of milling force is in good agreement with the experimental value, and the error value of milling force is less than 1%. By analyzing the relationship between tool wear per tooth and milling force, it is concluded that the milling force in the feed direction has the greatest impact on tool wear. Therefore, the radial force component can well characterize the tool wear, so as to improve the milling accuracy and efficiency.