Instantaneous milling force prediction and valuation of end milling based on friction angle in orthogonal cutting

The milling force has an important influence on tool wear and workpiece deformation, which is an important reference factor for selecting milling parameters. In this paper, based on the friction angle of the primary shear zone obtained from the orthogonal cutting simulation experiment, a three-dimensional instantaneous milling force prediction model is established, with an iterative model of ploughing force coefficient developed. By introducing the friction angle and establishing a new model of the tool-workpiece engagement area, the applicability of the prediction model of milling force is greatly improved, that is, based on a set of orthogonal cutting experiments, this model can predict the three-dimensional instantaneous milling forces under arbitrary geometric parameters of tool and cutting parameters. The accuracy of the milling force prediction model is verified by the milling experiment of aluminum alloy 2A14, and the prediction error of the milling force model is less than 30%. The results show that the relative error of average milling force decreases with the increase of cutting speed, so the prediction model of milling force has high accuracy under high cutting speed conditions.