Prediction of cutting forces in circular corner milling process

This paper proposes a precise approach to predict the cutting forces in circular corner milling. High precision corner milling process modeling requires the accurate formulation of undeformed chip thickness and the instantaneous calculation of cutter-workpiece engagement (CWE) geometry. An accurate and high-precision undeformed chip thickness model for circular milling is developed in this paper with the method of Taylor's expansion and geometrical analysis. The instantaneous calculation of cutter-workpiece engagement in the circular corner milling is also studied, which provides a new approach for the CWE calculations in three-axis milling. Cutting force simulation and analysis is given to show that this method of cutting forces prediction in corner milling process has high accuracy and computational efficiency.