A Dynamic Model for End Milling Using Single Point Cutting Theory

The dynamics of a milling process can significantly influence the surface quality and integrity of the finished part. Accordingly, various researchers have investigated the dynamics of milling processes using a hierarchy of models. Tlusty and Smith (1991) provides a review of these models. In recent years, several other researchers (e.g., Armarego and Deshpande, 1989; Montgomery and Altintas, 1991; Nallakatla and Smith, 1992) have also continued to enhance various aspects of such dynamic models. While these dynamic models provide significant insights into the cutting characteristics of a milling process, their utilization in process design has proven to be elusive. The accuracy of these models, however, depends significantly on the prediction of cutting force characteristics. Under the current state-of-the-art, detailed experimentations using actual set-up are necessary to make such predictions accurately. Experimentally obtained constants can vary widely from one milling situation to another, which in turn, significantly restricts their usefulness as predictive tools for process design.