Milling process simulation for the variable pitch cutter based on an integrated process-machine model

Milling process simulations provide a useful way to design and adjust the technical parameters of milling process. As the milling process involves coupling of multiphysics, interactions between the cutting force model and the dynamic model of the tool-spindle system must be analyzed in order to simulate the milling process precisely. This study proposes an integrated process-machine model based on computer graphics method for simulating the milling process of a variable pitch cutter. This method considers both the influence of the transitional surface and vibrations along different cutting directions. In this method, the cutting force model of the variable pitch cutter and the frequency response function (FRF) of the spindle system are first determined. Then, the interactive interface is established to evaluate the interaction between the cutting force model and vibration of the tool noses, which is calculated through an interaction effect. The undeformed chip thickness considering the vibration of the tool nose and the transitional surface is calculated using a computer graphics method and then input into the cutting force model. Finally, the model precisely predicts the cutting force, and surface appearance of the workpiece precisely is predicted by considering the vibration of the tool noses.