Prediction of Cutting Forces in Milling Stainless Steels Using Chamfered Main Cutting Edge Tool

Chung-Shin Chang
*

Abstract
To study the cutting forces, the carbide tips surface temperature, and the mechanism of secondary chip and main chip formation of face milling stainless steel with a chamfered main cutting edge has been investigated. Theoretical values of cutting forces were calculated and compared to the experimental results Force data from these tests were used to A

with SUS 304 stainless steel plate as a workpiece material.

estimate the empirical constants of the mechanical model and to verify its prediction capabilities. comparison of the predicted and measured forces shows good agreement.

A preliminary discussion is also Next, the tips mounted in

made for the design of special tool holders and their geometrical configurations.

the tool holders are ground to a chamfered width and the tool dimensions are measured by using a toolmaker microscope. Key Words: Face milling, oblique cutting, chamfered main cutting edge, stainless steel
*

Professor, Dept. of Mechanical Engineering, National Ilan University, I-Lan, Taiwan, 26014, R.O.C.

I. Introduction
The practical application of alloy steels in modern mechanical manufacturing is quite popular and most of these alloy steels are difficult to cut, especially stainless steel. The variety of structures and compositions

currently available in stainless steels provides a range of mechanical properties and corrosion resistance, which affords a high degree of design versatility [1]. for the production of flat surfaces. Face milling is a machining process used extensively Both

Intermittent cutting and high productivity rates characterize it.

simple and complex workpiece shapes can be face milled by [2, 3].

Lin [4] showed from the stand-point of

tool life by chipping on face milling stainless steel, the feed-rate range can be cataloged into three regions: in the high-feed rate region, the cutting edge of the tool is chipped with built-up edge; in the medium feed-rate region, the cutting edge of the tool is chipped with no built-up edge; whilst in the low feed-rate region chipping rarely occurs. It was also observed that a cutting speed of 85m/min is optimum to remove the However, the main failure mechanism of the cutting tool is wear than chipping Recently, in the interest of increased productivity, heavy cuts can produce

maximum volume of metal.

when face-milling stainless steel. good finish machined surface.

The cutting efficiency could increase significantly if a high power machine A good tool needs sufficient hardness and the appropriate

tool and cutting tools are selected properly.

geometry. Shaw [5] demonstrated silver-white chip (SWC) tools could decrease energy by 15 %, and

prolongs tool life by 20%, compared with that of conventional tools, but tool wear inevitable.

Hoshi [6]

studied extensively the characteristics of the built-up edge (BUE) and developed SWC tool in face milling method. The method involved tool geometries that produce a BUE which flows away continuously in the

form of a separated secondary chip. For an understanding of the cutting dynamics, Kim and Ehmann [7] showed the knowledge of the cutting forces is one of the most fundamental requirements. These

knowledges also give important information for cutting design, machine tool design and detection of tool wear and breakage. There have been many analyses of the three-dimensional cutting forces [8, 9].

Compared with the other factors, cutting force has a great effect on the dynamics of the cutting process as well as the machine tool structure; therefore a full understanding of cutting force variation is crucial. Usui

et al. [10] have presented a basic model with a single point tool and a nose-radius tool, applying the energy approach method to predict the cutting force. For predicting the correct cutting forces, however, shear plane

areas must be cooperated with the wear effects of tool edge during the cutting process. Young [11] had arranged a special experiment set-up, and performed a series of experiments. showed that a good correlation between the milling and turning was obtained for the same conditions. It He

concluded that to the use of steady state intermitted cut operation such as face milling is recommended. Chang [12] has presented that milling of medium carbon steel with chamfered main cutting edge tools could improve cutting efficiency. from his discussion. However, the effects of tool with face milling stainless steel were excluded

In this paper, the effects of sharp inserts on milling forces and the shape of chips are Theoretical results will compare with experimental

examined to predict the theoretical milling forces.

cutting forces for the chamfered main cutting edge tool in milling of stainless steel plate.

II. Methods of Solution

Pandey and Shan [13] employed a single shear plane model to develop an analytical force model for face milling. computerized. A force model for face milling stainless steel with chamfered main cutting edge tools which Nakayama [14] et al. investigated the relationship between the cutting forces, temperatures, deal with the realities of more complicated machining situations should be systematically organized and surface roughness and BUE; the results indicated that the cutting forces were low when BUE was present. A chamfered main cutting edge tool, which can produce a secondary chip, reduces the cutting force and aids thermal dissipation. The results indicated that, for ease of chip flow, the lead angle C s should fall in the range of 20 to 40 . according to Eq. (1). The edge of the negative radial angle r 1 lightly contacts the workpiece and Once C s , r 1 , r 2 and R were determined, the cut depth was selected The choice of the width of chamfer, We , the value of the negative radial angle, r 1 , participates in the cutting action.

positive radial angle, r 2 , and the value of C s will greatly affect the ease of chip flow and the resulting surface roughness of the workpiece.

We<f cos Cs, where f represents the feedrate, and C s denotes the lead angle of the tool

(1)

Based on the experimental results of Hoshi [6], and Chang [12], the basic force model for a sharp corner tool with a chamfered main cutting edge ( R = 0) shown in Fig. 1 was derived as follows:

(i) The energy method to predict cutting force

U=Us+Uf The shear energy (U s ) and the friction energy (U f ) were proposed by Usui [10] as: V cos e s sin cos e QV (3), and U f = Ft Vc = f t 0B1 dbVc = U S = FS V S = FS cos( e e ) [cos( e + e ) cos( e e )] (2)

(4)

Where 0B1 db is the integral width of chip flow direction along the tool face, (Fig. 2). B1 is the width measured in the direction orthogonal to the chip flow, db is an increment of integration in that direction, as shown in Fig. 2.

FS = S A, ft =

(5), and V S =

s t1 sin , (notation: f t is the frictional force in orthogonal cutting for unit width of [cos( + ) sin ]

V cos e cos ( e e )

(6)

cut and t 1 is the undeformed chip thickness (Fig. 2)) V sin e , Vc = cos( e e ) The relation between ' c and c on the tool face is:

(7)

' c = tan 1 [(tan c sin r 2 tan a cos a cos r 2 ]

values c , and

(8)

According to this equation, the shear plane can be verified by changing c over a small number of sin e = sin 1 (sin r 2 cos a cos c + sin c sin a ) (9)

where the symbol e represents the effective rake angle (rad), a denotes the axial angle (rad), e is the effective shear angle and equals to 0.581 e -1.139 (rad), is the friction angle (rad) which equals to exp (0.848 e -0.416) [10], s is the shear stress which equals to 571 - 19.9 e ( MN m 2 ) [15], and c is the chip flow angle which is determined by minimizing the total cutting energy U . The constitution of the shear plane area, A, and the friction area, Q, is plotted in Fig. 1, and they will be obtained from the following equations:

(ii) The shear areas in the cutting process for sharp tool
A = A1 + A 2 + A s A1 = t3
2

4 cos r 2 sin e cos c

2 2 2

4 cos 2 e

[1 +

cos 2 e sin e cos c

2 2

1 [sin2 c + ( sin e + cos 2 c

1

cos e cot e ) 2 2 sin c sin a (sin e + cos e cot e )]] 2 } 2 (the area of triangle BCE);

(10)

t tan c 2b ) 3 1 cos a cos r 2 2 A2 = {cos 2 e sin 2 e [sin c (sin e + cos e cot e ) sin a ] } 2 (the area of 2 sin e cos r 2 cos c t3 (

trapezoid CEFD), and

(11)

As =

W e cos r 1 ) 2 tan C s ( 2( cos a sin e )

(the area of triangle D' YJ )

(12)

A1 + A2 is the area of main chip, and As is the area of secondary chip, which is a triangule in Fig. 1. The area of the projected cross section Q is equal to Q1 + Q2 + Q3 . t3 1 b +b Q1 = ( 2 (the area of the trapezoid LBCD ); ) 2 cos a cos r 2 t b Q2 = 2 2 (the area of the rectangle CC ' DD' ); cos a
Q3 = We cos r1 tan C s (the area of triangle DD' Y ) 2 cos a
2

(13)

(14)
(15)

where coefficients of t1 , t 2 , t 3 , f 1 , b, b2 and b4 are described in Appendix A. According to the above investigations, the cutting force is a function of parameters r 1 , r 2 , a , d , W e , ref ,C S ,C e , f ,V and c . formation can be determined. energy U min . Once c had been determined, then e , e , s and that describe chip By changing the value of c in the developed computer program, the The angle c can be determined by considering the minimum

cutting force can be calculated.

The calaulation procedure for the cutting force is shown in Fig. 3. (17)

The cutting force, F H , can be determined by applying the equation by Reklaitis et al. [16] as: U min = V ( FH ) U min , (16); where U min = U s + U f and F H is the cutting force and V is the cutting speed. Therefore, cos e A s sin cos e Q U FH = ( FH )U min = min = { s + } V cos( e e ) [cos( e + e ) cos( e e )] and
( R t ) H = N t cos r 2 cos a + ( Ft ) U min sin e = ( FH ) U min

(18)

(19) (20)

where Ft =

s sin cos e Q [cos( e + e ) sin e ]

Hence, N t can be rewritten as [(FH )U min (Ft )U min sin e ] Nt = (cos r 2 cos a )

(21)

In Eq. (19) ( Rt ) H is the horizontal cutting force in the horizontal plane, N t is the normal force at the tip surface with minimum energy. Therefore, transverse cutting force, FT , and vertical cutting force, FV , can be expressed by the following: FT = N t cos r 2 sin a + Ft (sin c cos a cos c sin r 2 sin a ) (22)

FV = N t sin r 2 + Ft cos c cos r 2 .

(23)

Due to the size effects, a modified cutting force is presented in this paper to get more precise results. Besides the horizontal force F H , the plowing force F p due to the effects of the tool edge and the wear force FW due to the effects of flank wear [12] are considered in the prediction of the modified horizontal cutting force, ( FH ) M , as illustrated in Fig. 4. That is (25), and FW = y L f Vb (26)

(iii) Modified force model

(FH )M = (FH )U min + FW + FP

(24), F p = HB r L f

where HB is the Brinell hardness of the workpiece, r is the radius on the main cutting edge between the face and flank. Vb is flank wear of tips and for simplification, the value of Vb is set to be 0.05mm. L f is the contact length between the cutting edge and the workpiece and L p is the projected contact length between the tool and the workpiece, as referred to [12], can be determined according to the following conditions. Lf = f 1 cos C s f 1 cos C s cos C e d d ) sinC s + (28) + (27),and L p = ( cos C s [cos r 2 cos (C s C e )] cos C s [cos (C e C s ) cos r 2 ]

The modified transverse cutting force (FT degree of tool wears.

)M

is equal to FT (Eq. 21) plus a thrust force caused by the

The (FT )M is shown in Eq. (29). The modified vertical cutting force ( FV ) M is equal to, FV (from Eq. 23) plus a shear force caused by tool wears. of the workpiece y . This shear force can be estimated (Vb L p ) and the shear strength (29), and ( FV ) M = FV + L pVb y (30) The expression of ( FV ) M is shown in Eq. (30).

This thrust force can be estimated ( L pVb ) by the yield strength of the workpiece y .

(FT )M

= FT + L p V b y ,

If the Brinell hardness of the workpiece, HB , is given, the expression of y and y , are given by Cook [17] s = y 2 , y = HB .
FHH = (FH )M

(31) (32), and FTT = (FT )M cos C s + (FV )M sin C s ,

(33) (34)

Based on Fig.5, the final modified cutting force, FHH , FTT and FVV can be calculated by

FVV = (FV )M cos C s ( FT ) M sin C s (fo r Cs 0 )

Face milling is one of the most important machining processes, which inherently have a high metal removal rate due to multitooth cutting. In Fig. 6, each tooth of the cutter has an entry angle and exit angle, and both vary with the workpiece and cutter diameter, the values will alter at X = 0 o ~ 180o . To understand the whole process of the cutting force pulsation, the complete process ( i = 0 o , f = 180o ) will

be presented in this paper. motion.

In face milling, the cutter has a rotary motion and the workpiece has a plane

By contrast with the turning operation, as shown in Fig. 7, the workpiece carries out a rotary

motion and the tool has a plane motion. But as long as the feedrate is small, the cutting velocity, the radial angle ( r ), the axial angle ( a ), the undeformed chip thickness, and the normal rake angle, which all vary by less than 5% [18], so that the path can be approximated as a circle without much loss in accuracy. The

tooth path of a face-milling cutter is a cycloid as shown in Fig. 6. The comparison of tool geometry between the face milling cutter and turning tool is shown in Fig. 7. Where the radial angle, r 2 , the axial angle, a , and lead angle of face milling cutter are equal to the second normal side rake angle, s 2 , the back rake angle, b and the side cutting edge angle, C s , repectively. As shown in Fig. 6, the undeformed chip thickness of the tooth path is divided into a series of elements, 10 degrees in each element, in which undeformed chip thickness ( t 1 ) is the central cross section between both sides. Comparing the chip cross section with the turning process, it is realized that the f (feed per tooth) and d of face milling are equal to
f

(feed per revolution) and d (cutting depth) in turning, so that the undeformed chip thickness and (37)

cutting width W in face milling process are calculated by the following equations: t1 = f cos Cs (35), f = f sin X (36), and W = d cos Cs where f = feedrate (rev per tooth) .

Figure 7 shows the unit chip cross section and various cutting force components exerted on workpiece at cutting edge where FHH , FVV and FTT are equal to the cutting force components in turning. Since the directions and magnitudes of the elemental oblique cutting force components FHH , FVV and FTT will vary from element to element, these can be resolved into the fixed and practical directions X , Y and Z . cutting forces are given by FX = FHH cos X + FVV sin X (38), FY = FHH sin X FVV cos X (39), and FZ = FTT Thus the (40).

(iv) Experiment method and procedure

In previous sections, the cutting force model for various cutting conditions and tool geometries were derived. To verify these force models, experiments were conducted using the set-up in Fig. 8; a sampling rate of 1024 samples sec was found to be sufficient for the experiments. The experiments were on a vertical machining center using a plate face milling process without using any cutting fluids. It was required to measure the cutting force components FHH , FVV and FTT (Figs. 5 and 6) for a range of cutting conditions and tool geometrical factors. The machine tool used for the tests was a leadwell vertical machining center (MCV-OP) having a variable feed range with 1~10000mm/min, motor with speeds 60 ~ 6000rpm, rating up to 3. 7 5.5 kW . In measuring the cutting forces a Kistler type 9257B,
three-component piezoelectric dynamometer was used with a data acquisition system that consisted of Kistler type 5807A charge amplifiers, all measured data were recorded by a data acquisition system (Keithley Metro byte-DAS1600) and analyzed by the control software (Easyest). checked constantly by repeating the experiments. manufactured in house. The cutting tool used in the experiment was Sandvik P10 [19] and the workpieces were SUS 304. The experimental conditions were maintained the same for all tests as follows: (1) dry cutting; (2) cutting velocity,V = 75 m min( N = 250 rpm ) ; (3) cutting depth: d = 0.5 and d = 1 The reliability of the measurement data was Since the manufacturers do not provide tools with

selected combinations of lead, radial, axial and inclination angles, special tool holders were designed and

mm; (4) rate of feed: f = 50 mm min ; (5) the tool holder was vertical to the workpiece. Oblique milling tests were carried out for each tool. results were then averaged. discussion in sections III. In the test for each tool geometry the workpiece The was milled 170 mm in the feed direction, while the data were recorded three times at different depths.

The cutting force, the shapes of chips and tips wear were observed and

III. Results and Discussion (i) Shape of chips

The milling tests were described in the previous section. was 20 o , 30o and 40 o . Fig. 9 shows photographs of the chips obtained with the three tool holders (6 tips) when the nose radius of the tips was 0.03 mm and the lead angle It can be observed from the resulting chips that:
1. Due to the larger effective shear angles and smaller friction angles (revealed by the aid of the flow chart in

Fig. 3), the secondary chip was formed more obviously and flowed more easily under the situations of r1 = 30o and r 2 = 30 o , and shown in Figs. 9(a)-9(f). Therefore, r1 = 30 and r 2 = 30 are the ideal radial angles to produce secondary chips. 2. During the milling process, it is easier for the secondary chip to flow out, as a lead angle ( C s ) of the chamfered main cutting edge milling tool was 30o . 3. Regardless of the value of the nose radius, a secondary chip forms for r1 = 30o , r 2 = 30 and

C s = 30 o .

This result leads to the conclusion that C s , r1 and r 2 affect the formation of the secondary

chip but not R .

(ii) The cutting forces and current consumption

From Eqs. (10)-(15), the shear area A and projected area Q were calculated. After the shear area (A) and projected area (Q) were obtained, the shear energy per unit time ( U s ) and the friction energy per unit time ( U f ) were calculated from Eqs. (3)-(4). The theoretical principal component of the cutting force ( FH )U min was then obtained from Eqs. (16)-(18); the vertical theoretical cutting force ( FV ) and the transverse theoretical cutting force ( FT ) were obtained from Eqs. (19)-(23). The flank wears and plowing force must be taken into account in order to obtain the modified three-axis turning forces FHH , FVV and

FTT (Fig. 4) that were obtained from Eqs. (24)-(34) and the three axis milling forces FX , FY and FZ that
were obtained from Eqs. (35)-(40) respectively. The values of the theoretical, modified and experimental results for FX , FY and FZ are plotted respectively in Figs. 10-14. The following conclusions were obtained from these results. 1. Fuh and Chang showed that increasing the side rake angles s 1 and s 2 , decreases the cutting forces F HH , FVV and FTT as Ref. [15]. Similarly in this study, for a constant lead angle C s , and nose radius R=0 mm, Fig. 10-12, that increasing the radial angles r 1 and r 2 , decreases the

cutting forces F X , FY

and F Z .

Because the contact length between the chip and the tips is

shortened, the effective radial angle and effective shear angle are increased but the friction angle is decreased.

The symbols r 1 ( s 1 ), r 2 ( s 2 ), F HH , FVV FY and F Z are shown in Figs. 5-7. (Note: The side rake angle in the papers of Fuh and Chang [15] is denoted by s , here we use r , which is shown in Table 1 too.)
2. In Figs. 10-14, we find that in the case of a constant radial angles ( r1 and r 2 ), the increase of the lead

angle, C s , from 20 to 30 , will induce a decrease in the cutting force because the chip flows more easily and the secondary chip is produced more clearly. chip and the tip is decreased. Especially in this situation, the contact length between the However, if the lead angle is increased from 30 to 40 , the cutting force

will increase because the contact length between the chip and the cutter is increased [12].
3. In Figs. 10-14, the theoretical values and the experimental values for chamfered R = 0 (R<f), and

unchamfered milling tool show good agreement.

4. In Figs. 10-14, a face-milling tool with a chamfered main cutting edge decreases the cutting force about

20% more than an unchamfered main cutting edge milling tool. This is because the shear area of chamfered main cutting edge milling tools is smaller than that of unchamfered main cutting edge milling tools, as simulated from the flow chart of cutting force prediction in Fig.3, thus leading to the unstable cutting forces.
5. If the flank wear and the plowing force were taken into consideration, the final modified theoretical cutting

forces will be closer to the experimental values. 6. Figs. 10-12, show that FX , FY and FZ increase greatly with tooling on unchamfered main cutting edge.

(iii) Tip wear

The unchamfered main cutting edge with sharpness milling tool ( R = 0 ) has the most wear among the various tested tools, as shown in Fig. 15, because the tools with the largest cutting force produce a secondary chip with more difficulty.

IV. Conclusions
A new model has been constructed to predict the cutting forces of face milling, for the cases of chamfered, R = 0 ( R < f ), and unchamfered sharpness tool ( R = 0 ). The predicted cutting forces for face milling are in agreement with those obtained by experiments. With the increase of the first and second radial angles, the cutting forces FX , FY and FZ decrease. But when Cs = 30o , and r1 = r 2 = 30o , the cutting forces are at the lowest levels, so this is an ideal tool geometry because the areas of shear and friction are the smallest. Using chamfered main cutting edge milling tools under suitable cutting conditions, the This effect can also increase the impact value and the strength of tips, as well A new tool model is successful to calculate the variation of shear areas using chips flow away more easily. as avoiding the tool fracture. chamfered or unchamfered.

the energy approach and can predict the three-dimensional face milling cutting forces when the tool is either

Acknowledgements
The National Science Council, Taiwan, R.O.C. supported the work under grant No. NSC-91-2212-E-197-001

Normcultures
A: area of shear plane ( mm 2 ) theoretical horizontal cutting force (N) friction force (N) shear force(N) theoretical transversal cutting force (N) theoretical vertical cutting force (N) milling force in X-axis direction (N) milling force in Y-axis direction (N) milling force in Z-axis direction (N) feed rate of cutting position inclination angle (rad) main cutting edge radius (mm) nose radius(mm) cutting velocity (m/min) chip velocity (m/min) shear velocity (m/min) chamfering width (mm) rake angle (rad) axis direction angle (rad) entry angle (rad) exit angle (rad) alter entry angle (rad) side relief angle (rad) shear angle in orthogonal cutting (rad) yield normal shear stress ( N / mm 2 ) yield shear stress ( N / mm 2 ) shear stress ( N / mm 2 )

FH : Ft : Fs : FT : FV : FX : FY : FZ : f :
i:

r: R: V : Vc : Vs : We :

: a : i : f : X : ref : : y : y : s :

Appendix A
A. Variables for the tool with a sharp corner, Fig. 1 ( R = 0 )

t 1 = f cos C s (A1), t 2 =W e cos r 1 (A2) and t 3 = t 1 t 2 f1 = f W e cos r 1 (A4), b = d cos C s (A5), b4 = t 2 tan C s (A6), and b 2 = b b 4

(A3) (A7).

References
[1] Gray, A.G., Forming of Stainless Steels, Materials and Process Engineering Bookshelf, Published by the American Society for Metals (ASM), USA, pp.1-2 (1968) [2] Gu, F., Kapoor, S.G., DeVor, R.E. and Bandyopadhyay, P., An Enhanced Cutting Force Model for Face Milling with Variable Cutter Feed Motion and Complex Workpiece Geometry, Trans. of the ASME, J. of Manufacturing and Engineering, 119, pp. 467-476 (1997) [3] Martelloti, M.E., An Analysis of the Milling Process, Trans. of the ASME, J. Part II, 63, pp. 677-700 (1945) [4] Lin, T.R., Reliability and Failure of Face-Milling Tools when Cutting Stainless Steel, Journal of Materials Processing Technology, pp. 41-46 (1998) [5] Shaw, M.C., Metal Cutting Principles, Published by Oxford University Press, New York, pp. 335- 367 (1984) [6] Hoshi, T., "Recent Development in Silver White-Chip (SWC) Cutting, "Proc. Int. Conf. on Cutting Tool Materials, Ford Mitchell, KY, USA, pp. 15-17 (1980) [7] Kim, H.S. and Ehmann, K.F., A Cutting Force Model for Face Milling Operations, Int. J. of Machine Tool & Manufacturing, Design, Research and Application, 33 (5), pp. 651-673 (1993) [8] Kline, W.A., DeVor, R.E. and Lindberg, J.R., The Prediction of Cutting Force in End Milling with Application to Cornering Cuts, Int. J. Machine Tools & Manufacture, Design, Research and Application, 22(1), pp. 7-13 (1982). [9] Fu, H.J., DeVor, R.E. and Kapoor, S.G., A Mechanistic Model for the Prediction of the Force System in Face Milling Operations, Trans. of the ASME, 106, pp. 81-88 (1984) [10] Usui, E., Hirota, A. and Masuko, M., "Analytical Prediction of Three Dimensional Cutting Process: part 1, Basic Cutting Model and Energy Approach," Trans. of the ASME, 100, pp. 222-228 (1978) [11] Young, H.T., "Analysis of Force Pulsation in Intermittent Cut Operation," The 5th National Conf. on Mechanical Engineering, CSME, Taipei, pp.717-734 (1988) [12] Chang, C.S. A Study of High Efficiency Face Milling Tools, J. of Materials Processing Technology, 100, pp. 12-29 (2000) [13] Pandey, P.C. and Shan, H.S., "Analysis of Cutting Forces in Peripheral and Face Milling Operations," Int. J. Prod. Res., 10(4), pp.379-388 (1972) [14] Nakayama, K., Shaw, M.C., and Breuer, R.C., Relationship between Forces, Temperatures Built-up Edge and Surface Finish, Annals of CIRP 14, pp.211-233 (1966) [15] Chang, C.S., Turning of Stainless Steel with Chamfered Main Cutting Edge Tools, J. of Materials Processing Technology, 10(3), pp. 473-492 (1995) [16] Reklaitis, G. V., Ravindran, A. and Ragsdell, K.M., Region-Elimin. Method, Engineering Optima Methods and Application, Wiley-Interscience Press, New York, pp.37-46 (1984). [17] Cook, N.H., The Mechanics of Chip Formation in: Manufacturing analysis, Addison-Wesley, New York, pp.37-38 (1969) [18] Young, H.T. ,"Application of Predictive of Machining Theory to More Complicated Processes Including Single-Point Oblique Cutting Tools with Other than Single Straight Cutting Edges and Milling and Experimental Verification," Ph. D., Universities of New Wales, Australia (1986) [19] Brookes, K. J. A., World Dictionary, Handbook of Hard metals and Hard Materials, Int. Carbide Data Handbook, UK, pp. 10-12 (1992).

Table 1 Tool geometry specifications

Fig. 1 Detail model of the shear plane A(A=A1+A2+AS) and the projected area Q(Q= Q1+Q2+Q3) with the chamfered main cutting edge, f>R, R=0,(r : radial angle, e: shear angle, c : chip flow angle)

Fig. 2 Calculation of friction forces on the tool face, f>R, R=0 (r : radial angle, b=a, b: parallel back angle, : friction angle, e: shear angle, c: chip flow angle, t1=undeformed chip thickness)

Fig. 3

Flow chart of cutting force prediction

Fig. 4

The composition of modified (FH)M

Fig. 5 Rotation of main cutting edge and positive directions of force components (final force)

Fig. 6 Cutting forces model of face milling and cutting geometric relationships

Fig. 7 Tool geometric angles between (a) turning and (b) milling cutter

Fig. 8

experimental set-up

(a) r1=-10, r1=-10

(b) r1=-30, r1=-30

(c) r1=-10, r1=-10

(d) r1=-30, r1=-30

(e) r1=-10, r1=-10

(f) r1=-30, r1=-30

Fig. 9 Chip shapes with: (a)(b) CS=20; (c)(d) CS=30; and (e)(f) CS=40;of chamfered cutting edge tools at f>R, R=0, f=45mm/min, d=0.5mm and V=75m/min

700 600 500 400 300 200 100 0 -100 -200

100

120

140

160

Fz: theoretical values (unchamfer edge, R=0mm) Fy: theoretical values (chamfer edge, sharp,R=0) Fx: theoretical values (chamfer edge, sharp,R=0) Fx: theoretical values (unchamfer edge, R=0mm) Fy: theoretical values (unchamfer edge, R=0mm) Fz: theoretical values (chamfer edge, sharp,R=0)

Fig. 10 Theoretical cutting forces: horizontal (FX), transverse (FY) and vertical (FZ) vs rotating angles ( ) for unchamfered and chamfered (f>R, R=0) tool at Cs=20, r1=-30 and r2=30, f=45mm/min, d=0.5mm and V=75m/min (stainless steel)

180

20

40

60

80

650 550 450 350 250 150 50

10 12 14 16 18

-50 -150 -250

20

40

60

80

Fx: theoretical forces(chamfer edge, sharp, R=0) Fy: theoretical forces(chamfer edge, sharp, R=0) Fz: theoretical forces(chamfer edge, sharp, R=0) Fx: theoretical forces (unchamfer edge, R=0mm) Fy: theoretical forces (unchamfer edge, R=0mm) Fz: theoretical values (unchamfer edge, R=0mm)

Fig. 11 Theoretical cutting forces: horizontal (FX), transverse (FY) and vertical (FZ) vs rotating angles ( ) for unchamfered and chamfered (f>R, R=0) tool at Cs=30, r1=-30 , r2=30, f=45m/min, d=0.5mm and V=75m/min(stainless steel)
750 650 550 450 350 250 150 50 -50 -150 -250
80 10 0 12 0 14 0 16 0 18 0 20 40 60 0

Fx: theoretical values (chamfer edge,sharp, R=0) Fy: theoretical values (chamfer edge, sharp, R=0) Fz: theoretical values (chamfer edge, sharp, R=0) Fx: theoretical values (unchamfer edge, R=0mm) Fy: theoretical values (unchamfer edge, R=0mm) Fz: theoretical values (unchamfer edge, R=0mm)

Fig. 12 Theoretical cutting forces: horizontal (FX), transverse (FY) and vertical (FZ) vs rotating angles ( ) for unchamfered and chamfered (f>R, R=0) tool at Cs=40, r1=-30 and r2=30, f=45mm/min, d=0.5mm and V=75m/min (stainless steel)

(a) (FX) unchamfered tool

(b) (FX) chamfered tool

(c) (FY) unchamfered tool

(d) (FY) chamfered tool

(e) (FZ) unchamfered tool

(f) (FZ) chamfered tool

Fig. 13 Experimental cutting forces: (a) (b) horizontal (FX) ; (c)(d) transverse (FY) ; and (e)(f) vertical (FZ), vs cutting time(sec) for an unchamfered and chamfered (f>R, R=0) tool at CS=20, r1=-30 and r2=30, f=45mm/min, d=0.5mm and V=75m/min (stainless steel)

(a) (FX) unchamfered tool

(b) (FX) chamfered tool

(c) (FY) unchamfered tool

(d) (FY) chamfered tool

(e) (FZ) unchamfered tool

(f) (FZ) chamfered tool

Fig. 14 Experimental cutting forces: (a) (b) horizontal (FX); (c)(d) transverse (FY) ; and (e)(f) vertical (FZ), vs cutting time(sec) for an unchamfered and chamfered (f>R, R=0) tool at CS=30, r1=-30 and r2=30, f=45mm/min, d=0.5mm and V=75m/min(stainless steel)

top view

top view

front view

front view

(a) unchamfered tool (b) chamfered tool Fig. 15 The wear of tips (a) an unchamfered (R=0) and (b) a chamfered (f>R, R=0) main edge tool at CS=30, r1=-30 and r2=30, f=45m/min, d=0.5mm and V=75m/min (stainless steel)