Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Abstract

The aerospace industry utilizes nickel-based super-alloys due to its high level of strength and corrosion resistance. To evaluate milling strategies regarding tool wear, the prediction of forces during these cutting operations is essential. This comprises the determination of the undeformed chip thickness. Due to the complex interdependencies of tool engagements, the determination of these thicknesses is challenging. A geometric physically-based simulation system was extended by a novel time-discrete envelope model to increase the precision of the calculated undeformed chip thicknesses. In order to take tool wear into account, digitized topographies of cutting inserts in different states of tool wear were modelled.