Hybrid numerical-analytical approach for force prediction in end milling of 42CrMo4 steel

Abstract

This paper presents computational method for prediction of cutting force components during end milling process. Introduced method is a hybrid model combining finite element analysis (FEA) with classical analytical approach. Explicit 2D FE analysis is used to determine specific cutting force coefficients for specified tool geometry and workpiece material. Mechanistic analytical model utilizing data from FEA models transforms cutting force components Fc and FcN from tool-in-hand coordinate system into force components Ff and FfN of machine coordinate system yet additionally providing time history of forces by presenting them as a function of cutter rotation. Predicted forces from hybrid model are compared with empirical measurements of end milling process.