Numerical Simulations of the Cutting Forces in an End Milling Process with Process Damping, Tool Runout and Variable Pitch Effects

Milling cutters with runout, process dampening, and variable pitch did not solve milling difficulties because they did not address the regenerative chatter mechanism. When the phase difference between two waves varies from tooth to tooth, it throws off the regeneration process. The focus of this study is on devising a quick and accurate technique to quantify these influences during end milling. To enhance production quality and process stability while decreasing tool wear and machining costs, these methods may be included into an adaptive model for managing cutting force. The simulation results show that the cutting forces in end milling are small as compared to conventional scale cutting. In this study, an alternative process damping model has been presented for end milling based on an equivalent viscous damping approach. Furthermore, the technique is used to investigate how different tool geometries affect stability tendencies in variable pitch milling. Some novel phenomena are shown and discussed for certain parameter combinations.