Research on Cutting Force Modeling and Machining Performance of Discrete-Edge End Mill

Area of Science:

• Mechanical Engineering
• Manufacturing Technology
• Materials Science

Background:

• Cutting force prediction in discrete-edge end mills is challenging due to complex formation.
• Existing models often lack accuracy for these tools.
• Optimizing machining processes requires precise force modeling.

Purpose of the Study:

• To develop a high-precision cutting force model for discrete-edge end mills.
• To improve the accuracy of cutting force prediction.
• To provide a theoretical basis for optimizing cutting tool design and machining processes.

Main Methods:

• An effective chip slot function was developed to characterize cutting edge engagement.
• The instantaneous uncut chip thickness theory was applied.
• A new cutting force model was formulated for discrete-edge tools.
• Experimental validation was performed and compared to continuous-edge tools.

Main Results:

• The proposed model achieved an average prediction error of 4.82%, with a maximum error below 10%.
• Discrete-edge end mills reduced cutting forces (Fx by 7.2%, Fy by 3.2%) and suppressed vibrations (13.5% and 21.9%).
• Surface roughness was reduced to approximately one-sixth compared to conventional tools.

Conclusions:

• Discrete-edge end mills offer significant advantages in machining stability, cutting force control, and surface quality.
• The developed cutting force model is accurate and practically applicable.
• This research provides a foundation for high-performance cutting tool design and process optimization.