Finite element analysis of the dynamic cutting force distribution in peripheral milling

Among the machining errors generated in the peripheral milling the dimensional accuracy and surface roughness play a fundamental role in the quality of the machined component in the automotive and aerospace industry. The inadequacy of the surface roughness and the imprecision of the dimensional accuracy brings to the rejection of the part that causes financial loss and productivity slowdown. In this paper an analysis of the machining errors due to the cutting forces in peripheral milling was performed by means of a numerical model based on the finite element method. The dynamic cutting forces distribution were evaluated for several cutting conditions that varied with the effective rake angle, the axial depth of cut the radial depth of cut and the feed per tooth per revolution. The model was tested with the cutting forces measured by Yucesan and Altintas [1] in field trials on a titanium alloy. An analytical model furnished by Liu et al. [2] and calibrated with the Yucesan's results gave a benchmark to the discussion of the results of this paper.