Development and implementation of a novel split-wise model to predict the cutting forces in milling of Al2024 for minimum error

Abstract This research study is devoted to propose a newly developed split-wise model to predict the cutting forces. The proof-of-the-study is achieved by implementing this model in milling Al2024 for the minimum error. The developed model is based on the classical shifted linear model used in the published literature. This model includes the calculation of the milling tool considering individual teeth, which leads to the determination of 6 force coefficients of different values per tooth. The experiments were conducted on milling Al2024 for two set of experiments ( V fz = 375-675 m/min, a e = 4-12 mm, a p = 0.5-1 mm, D =16 mm) and ( V fz = 220-440 m/min, a e = 0.5- 1 mm, a p = 0.5-1mm, D =2 mm). For the first set, the comparative error determined from the split-wise and classic models is 5.6% and 7.8%, respectively. For the second set, the error is 11% and 15.7%, respectively. Therefore, the use of the split-wise model is highly recommended for the prediction of the cutting force at low tool diameters. The study findings have shown the great capacity of the model to adapt to the runout, especially at low-scale milling where the spindle runout is amplified. Currently, the proposed study uses the optimal force coefficients, which were minimized via a cost function process.