A new method for cutting force prediction in peripheral milling of complex curved surface

The instantaneous uncut chip thickness and entry/exit angle of tool/workpiece engagement vary with tool path, workpiece geometry and cutting parameters in peripheral milling of complex curved surface, leading to the strong time-varying characteristic for instantaneous cutting forces. A new method for cutting force prediction in peripheral milling of complex curved surface is proposed in this paper. Considering the tool path, cutter runout, tool type(constant/nonconstant pitch cutter) and tool actual motion, a representation model of instantaneous uncut chip thickness and entry/exit angle of tool/ workpiece engagement is established firstly, which can reach better accuracy than the traditional models. Then, an approach for identifying of cutter runout parameters and calibrating of specific cutting force coefficients is presented. Finally, peripheral milling experiments are carried out with two types of tool, and the results indicate that the predicted cutting forces are highly consistent with the experimental values in the aspect of variation tendency and amplitude.