Cutting power modeling in relation to machine kinematic behavior for high-speed milling

High-speed milling (HSM) stands for a revolutionary approach to machining complex parts that emphasizes high cutting speeds and rapid feed rates in order to enhance productivity and surface quality. Complex part and tool path geometries, as well as increased feed rates, during machining lead to instability of the cutting process. Solving this problem must be preceded by the prediction of feed rate and cutter-workpiece engagements as accurately as possible, as they have a significant impact on the evaluation of cutting power and energy. In this research work, a modeling approach for cutting power prediction is presented. The developed model is based on instantaneous material removal rates. As a matter of fact, it takes into account not only machining parameters but also tool path geometry, feed rate variation, cutter-workpiece engagements, uncut chip thickness, and workpiece materials. To achieve this target, the theoretical study was processed in two steps. The first step focuses on feed rate modeling, whereas the second centers around calculating the angle of engagement and instantaneous uncut chip thickness when milling the connection between linear and circular profiles in different combinations. High-speed machining of aluminum part was performed to validate the goodness of fit of the model, whose maximum deviation is 11.69%. The results reveal that the instantaneous uncut chip thickness is largely influenced by the kinematic performance of the machine tool and the change in engagement angle. In order to respect its kinematic performance, the machine slows down the motion of the tool at the transition between linear and circular interpolation. This instability in the real feed rate affects the instantaneous uncut chip thickness, which is therefore a factor inducing the variation of the material removal rate (MRR) and consequently the value of the cutting power.