Mechanistic Cutting Force Prediction Model for Plunge Milling Considering Cutter Runout

As a kind of promising process for mass material removal in rough and semi-rough machining of hard-to-machine materials, plunge milling receives wide concerns and is often considered as one of the most effective methods in metal cutting operation, especially in aircraft industry. The cutting force in plunge milling operation differs from that in side milling or end milling for the complex geometries. To clarify the force based cutting mechanisms, a systematic study on cutting force modeling is conducted in this paper based on the precise cutting geometry which considers both the real-time uncut chip thickness calculation and cutter runout. The deduced cutting force model can be used for different cutting conditions in plunge milling process. Then, series of plunge milling operations with various cutting steps are implemented to verify the proposed force model. The results indicate that the predicted values show quite good agreement with the measured cutting forces.