| In this thesis, a new approach to predict cutting forces in helical end milling is presented. The approach is based on utilizing material constitutive law, tool geometry and process parameters in a mechanistic format to predict the milling force components. The approach minimizes the need for experimental data to determine the specific cutting force coefficients as is the case with general mechanistic approach. Experiments are only performed for the verification of model predictions. The cutting and thrust forces are calculated based on Oxley's machining theory, however, the model is further extended by substituting Johnson-Cook's constitutive material model for the counterpart used by Oxley and Coworkers. This approach generalized the applicability of the model to a wide range of materials commonly used in industry. The validity of the extended Oxley's model has been examined by comparing the predictions with experimental data for AISI1045 steel and three other materials (AL-6061, AL7075 and Ti-6Al-4V) from open literatures. |
