Cutting Force Prediction of Plunge Milling Based on Precise Cutting Geometry

As one of the most effective methods, Plunge milling is widely used for mass material removal in rough and semi-rough machining of heat-resistant-super-alloys in metal cutting. The cutting force in plunge milling operation differs from that in side milling or end milling for the cutting geometry is more complex in plunge milling. In this paper, a new cutting force model is developed based on the more precise cutting geometry in plunge milling process. The cutting step is taken into account for real-time uncut chip thickness calculation as well as radial cutting width in the proposed cutting model. In the last, the sample cutting tests are carried out to indicate the correctness of the proposed cutting force model.