Analysis of the Mechanics of Machining with Tapered End Milling Cutters

The analytical prediction of forces in a tapered mill is of vital interest to the accurate machining of complex blade shapes for the aerospace industry. Failure of these cutters is more often by chipping and fracture as opposed to gradual wear. Geometry of the cutters along with duration and length during cutting is analyzed using known parameters. The influence of the geometrical parameters on the spatial distribution of cutting forces is derived from kinematics and the basic shearing processes. Shear strain is approximately obtained with the use of Stabler’s rule. Stress on the shear plane is found from appropriate shear stress-strain curves. A coefficient of friction on the cutting edge is used to evaluate the shear as well as normal forces. As a consequences, torque experienced by the cutter is evaluated. Finally, verification of the analysis is presented through sample calculations and correlations with experimental data measured with a dynamometer.