Abstract: A finite element model based on helix primary cutting edge is presented due to current oblique cutting numerical simulation’s shortcomings, in which the tool edge is straight. Then, milling process of aerospace aluminum alloy-7050-T7451 was simulated based on the presented oblique cutting model, and cutting force under the given cutting conditions is gained. A milling force experiment is carried out, and a good agreement between simulation and experimental data is achieved, which proves that the finite element model presented in this paper is correct, and milling force can be predicted by using the model. The study will be a base for process parameter optimization, tool’s optimization selection and design of aluminum alloy milling process, and also a new way to control machining distortion of monolithic components.

Key words: aluminum alloy, helix end milling, single edge oblique cutting, numerical simulation