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<p>Accurate milling force model is crucial for process parameters optimization, machining quality control, and tool condition monitoring. Although prior studies have recognized the influence of tool geometry and dynamic effects on milling forces, research remains limited in modeling the coupling of multiple geometric features and dynamic effects, particularly for indexable end mills. Based on the micro element milling force model, this paper proposes an enhanced model which simultaneously incorporates tool geometric characteristics (including nose radius, axial mounting inclination, and the trochoidal trajectory of the tool tip) and dynamic effects (such as tool runout and regeneration effect). The classical micro element model is first modified by accounting for the impact of insert axial inclination and nose radius on the tool-workpiece contact behavior. A static-dynamic coupled instantaneous undeformed chip thickness (IUCT) model is then developed by incorporating the static IUCT model for different width-of-cut types, while dynamic displacements due to the regeneration effect are computed using the frequency domain response method. Furthermore, a tool runout parameters identification method combining the time and frequency domains is proposed. Finally, the proposed model is validated through a series of comparative experiments. The results demonstrate that the proposed model improves prediction accuracy of milling forces in the <i>x</i>, <i>y</i>, and <i>z</i> directions compared with the classical milling force model, and better captures the force-response variations associated with tool geometry and dynamic effects.</p>

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Modeling of milling force for indexable end milling considering tool geometry and dynamic effects

  • 期刊论文

  • 发表日期：

    2026年6月19日

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  • Lei Song,
  • Chunping Yan,
  • Mao Yang,
  • Jiacai Liu,
  • Jing Song

摘要

Accurate milling force model is crucial for process parameters optimization, machining quality control, and tool condition monitoring. Although prior studies have recognized the influence of tool geometry and dynamic effects on milling forces, research remains limited in modeling the coupling of multiple geometric features and dynamic effects, particularly for indexable end mills. Based on the micro element milling force model, this paper proposes an enhanced model which simultaneously incorporates tool geometric characteristics (including nose radius, axial mounting inclination, and the trochoidal trajectory of the tool tip) and dynamic effects (such as tool runout and regeneration effect). The classical micro element model is first modified by accounting for the impact of insert axial inclination and nose radius on the tool-workpiece contact behavior. A static-dynamic coupled instantaneous undeformed chip thickness (IUCT) model is then developed by incorporating the static IUCT model for different width-of-cut types, while dynamic displacements due to the regeneration effect are computed using the frequency domain response method. Furthermore, a tool runout parameters identification method combining the time and frequency domains is proposed. Finally, the proposed model is validated through a series of comparative experiments. The results demonstrate that the proposed model improves prediction accuracy of milling forces in the x, y, and z directions compared with the classical milling force model, and better captures the force-response variations associated with tool geometry and dynamic effects.