Study on chip shape and cutting force model of milling process in any direction of space

This paper considers the calculation process for chip shape and cutting force of milling process in any direction of space.In the milling process with the existence of lead and tilt angle, the edges and boundary curves go through the process of one intersection, two intersections, tangency and non intersection in a milling cycle, thus the chip thickness needs to be calculated in various regions. The milling force is calculated by using the differential method. Then by comparing the milling forces when the lead angle is 5° and the tilt angle is 10° with when there is no inclination angle, the influence of inclination angle on machining process is studied. Meanwhile, by comparing the milling forces calculated by geometric analysis method with those calculated by classical Altintas model, the validity of the proposed method is verified. In addition, by comparing the milling forces obtained using the classical Altintas model with those obtained in published literature, the rationality of the method is further demonstrated.