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Procedia Manufacturing 32 (2019) 42–49
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The
The 12th
12th International
International Conference
Conference Interdisciplinarity
Interdisciplinarity in
in Engineering
Engineering

Analytical
Analytical Calculation
Calculation of of Cutting
Cutting Forces
Forces
Manufacturing and
and Analysis of their Change at 3-D Milling
Analysis
Engineering of
Society their Change
International at
Conference3-D
2017,Milling
MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
Victor
Victor A. Batuevaa,Victor
A. Batuev ,Victor V.
V. Batuev
a
Batueva,, Dmitrii
Dmitrii V.
V. Ardashev
a,
Ardasheva,a *,
*, Leonid
Leonid V.
V. Shipulin
a
Shipulina,,
Costing models for capacity S.optimization in Industry 4.0: Trade-off
0F

Anastasia
Anastasia S. Degtyareva-Kashutina
0F

a
Degtyareva-Kashutina
between
a
used
South Ural State
a capacity
University, and
76, Lenin Avenue, operational
Chelyabinsk, efficiency
454080, The Russian Federation
South Ural State University, 76, Lenin Avenue, Chelyabinsk, 454080, The Russian Federation

A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract
Abstract a
University of Minho, 4800-058 Guimarães, Portugal
b
Unochapecó, 89809-000 Chapecó, SC, Brazil
The empirical dependencies of cutting forces when milling spatially complex surfaces account for a narrow range of conditions
The empirical dependencies of cutting forces when milling spatially complex surfaces account for a narrow range of conditions
and do not consider the continuous change of geometrical parameters of the cutting area. Thus, currently, the task is to develop
and do not consider the continuous change of geometrical parameters of the cutting area. Thus, currently, the task is to develop
analytical force dependencies to study and control the process of multi-axis milling at CNC machines. This article contains
analytical force dependencies to study and control the process of multi-axis milling at CNC machines. This article contains
equations which set the functional interconnection between the cutting force in each moment of the cutter tooth turn with the
Abstract
equations which set the functional interconnection between the cutting force in each moment of the cutter tooth turn with the
slope angle of the work surface and the wear degree of the cutting edge in a wide range of variables. The adequacy of the
slope angle of the work surface and the wear degree of the cutting edge in a wide range of variables. The adequacy of the
developed
Under theanalytical
conceptdependencies
of "Industrywas4.0",
proven.
production processes will be pushed to be increasingly interconnected,
developed analytical dependencies was proven.
information based on a real time basis and, necessarily, much more efficient. In this context, capacity optimization
© 2018
© 2018
2019 The Authors. Published
The Authors. Published byby Elsevier
Elsevier Ltd.
Ltd.
goes
© beyond
The the traditional
Authors. Published aim
by of capacity
Elsevier Ltd.maximization, contributing also for organization’s profitability and value.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is anlean
Indeed, open access article under
management the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review underand continuous
responsibility improvement
of the approaches
12th International Conference suggest capacity optimization
Interdisciplinarity in Engineering.instead of
Selection and peer-review
maximization. The studyunder responsibility
of capacity of the 12thand
optimization International Conference
costing models is anInterdisciplinarity in Engineering.
important research topic that deserves
contributions from both the practical and theoretical perspectives. This paper presents
Keywords: spatially complex surface; 3D milling process; analytical models; cutting forces; milling. and discusses a mathematical
Keywords: spatially complex surface; 3D milling process; analytical models; cutting forces; milling.
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might hide operational inefficiency.
The The
© 2017 main meansPublished
Authors. used to by automate the mechanical operation of parts with spatially complex shapes are CNC
Elsevier B.V.
The main means used to automate the mechanical operation of parts with spatially complex shapes are CNC
millers. Theunder
Peer-review highresponsibility
performanceofofthethis equipment
scientific can be
committee of achieved primarilyEngineering
the Manufacturing by increasing theInternational
Society accuracy ofConference
3D milling,
millers. The high performance of this equipment can be achieved primarily by increasing the accuracy of 3D milling,
which can result in the reduction of allowances for further final machining and, thus, reduce lab or hours for
2017.
which can result in the reduction of allowances for further final machining and, thus, reduce lab or hours for
fabrication operations.
fabrication operations.
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

1. Introduction
* Corresponding author. Tel.: +7-922-230-48-07; fax: +7-351-267-92-73.
* The
Corresponding
cost author.
of idle Tel.: +7-922-230-48-07;
capacity is a fundamentalfax:information
+7-351-267-92-73.
for companies and their management of extreme importance
E-mail address: ardashevdv@susu.ru
E-mail address: ardashevdv@susu.ru
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
in several©ways:
2351-9789 tons
2018 The of production,
Authors. available
Published by Elsevier Ltd.hours of manufacturing, etc. The management of the idle capacity
2351-9789 © 2018 The Authors. Published by Elsevier Ltd.
This is an Afonso.
* Paulo open access
Tel.:article under
+351 253 510the761;
CC BY-NC-ND
+351 253license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CC fax:
BY-NC-ND 604 741
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection
E-mail and peer-review
address: under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
psafonso@dps.uminho.pt
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2019responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2019.02.181
 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49 43
2 V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000

The objective of the efficient use of CNC machines can be achieved only by profound study of the 3D milling
process. Since milling results from force interaction of the cutting tool with the work material, all researchers try to
develop cutting force models which set the interconnection of numerous factors influencing the cutting forces to
analyze and control this multi-factorial process.
Nomenclature

a cut thickness, mm
C, xa, xv empirical coefficients depending on the work material and the tool’s face angle;
dL surface element of the cutting edge;
fi instant area of the cut layer, mm2;
k empirical coefficient depending on the relative position of the cutting tool and the work;
lb size of the blunting area of the cutter teeth, mm;
P marginal hardening, MPa;
p specific cutting force, N/mm2;
PN normal force, N;
Pri radial component of the cutting force, N;
PS shear force, N;
Px axial component of the cutting force acting in the direction parallel to the cutter’s rotation axis, N;
Py radial component of the cutting force acting in the direction perpendicular to the cutter’s rotation axis, N;
Pz main component of the cutting force acting at a tangent from the motion path of the cutter blade’s points, N;
Pxy resulting radial-axial component of the cutting force acting in the normal direction to the cutting edge, N;
Px(c), Py(c) Pz(c) the cutting force components of the cut layer’s plastic deformation, N;
Pxy(fr) force of the chip friction against the tool’s face surface, N;
Pz(fr) force of work metal friction against the tool’s back surface, N;
Pzi main component of the cutting force acting on the surface element of the cutting edge, N;
R radius of mill, mm;
Rc resulting cutting force of the cut layer’s plastic deformation, N;
Sz feed per cutter tooth, mm/tooth;
V speed of the main cutting motion, m/min;
Vi current speed value of the main cutting motion in the point of the curvilinear profile of the cutter’s cutting edge
under consideration, m/min;
Vmax circumferential displacement speed of the curvilinear cutting edge point most remote from the cutter axis, m/min;
αc cutter back angle, o degree;
β angle between the shear line and the direction of the resulting Rc, o degree;
β1 shear plane angle, o degree;
μ friction coefficient of the cutting end material against the work material;
σ0 conventional yield strength of the work material, MPa;
σi stress intensity in the moving volume of deformed metal characterizing metal resistance to the plastic yield, MPa;
ψ current turn angle of the cutter teeth, o degree;
ω slope angle of the work surface, o degree;
γc cutter face angle, o degree;
η empirical proportionality coefficient depending on the cutter’s face angle, the thickness of the cut and the
blunting area of the cutter teeth;
φ cutter standard pressure angle, o degree;
φi standard pressure angle in the point of the cutter’s cutting edge under consideration, o degree;
φu, φl standard pressure angle of the upper and lower allowance limits, o degree.

2. Analysis of the force dependencies when milling spatially-complex surfaces

High-curvature parts to be worked by the multipoint-cutting tool – milling – are widespread in modern
mechanical engineering. One of the restrictions for such parts is the working accuracy connected to the value of the
milling force components acting throughout the processing.
J. Feng, Zh. Tao and Y. Lan [1] dealt with the development and study of the force dependencies in the milling of
works with curvilinear surfaces. They determined the surface by the helix structure and the movement of the milling
44 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49
V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000 3

tool. After that, the projected area of the sculptured shear surface in three directions determines the milling forces in
the three directions, respectively. Finally, the analytical model of milling forces based on the sculptured shear
surface is built, and this analytical model is verified by milling experiments. L. Shan, B.G. Martin and D. Zuomin
[2] considered milling with a small diameter tool: when one tooth of the cutting tool crosses the minimum chip
thickness boundary, the tool would enter into the ploughing zone with no chip formation. Therefore, it is significant
to predict the ploughing volume and forces in micro-milling. G. Urbikain, E. Artetxe, L. Norberto López de Lacalle
[3] offered a mathematical model based on the numerical discretization of barrel cutters to predict the cutting forces.
The work of V. Gyliene and V. Eidukynas [4] considers the influence of the geometry of the milling cutter on the
cutting forces. The particularity of the milling process is the discontinuity of chip removal assuming the chip cross-
section as well as the complexity of milling tool geometry. M. Wan, Y-Ch. Ma, K. Feng, W-H. Zhang [5] offered a
model based on the static or dynamic cutting processes. A unified proportional form is used to express ploughing
forces as a function of the volume of the materials extruded under the clearance face of the tool, and the
corresponding proportional scale is named the ploughing force coefficient. The work of Kunpeng Zhu and Yu
Zhang [6] proposes improved instantaneous milling force per tooth, with the inclusion of the tool run-out effect. W.
Huang, X. Li, B. Wang, J. Chen, and J. Zhou [7] describe a novel cutting force model for cylindrical end cutters,
discretizing the end cutter along its circumferential direction. In developing force models during milling, other
factors, for example, self-oscillations, were also considered. Thus, G. Totis, P. Albertelli, M. Torta, M. Sortino and
M. Monno [8] offered a model to predict the stability borders when the cutter diameter is relatively large in
comparison with the tooling system overhang and when curved or inclined cutting edges are applied. The authors’
model was verified by the simulation study methods. Adaptive systems were also offered to control the milling
process. For example, the system offered by M. Schwenzer, O. Adams, F. Klocke, S. Stemmler, D. Abel [9] allows
for the adaption of the tool advance value and for the adjustment of its path. D.M. Rosca, M.A. Vasiloni, M.A.
Folea [10] offered a new method to calculate the cutting forces at small-depth milling using a tool with a working
circumferential part. The results obtained by the authors allow for the implementation of working operations in
dynamic stability conditions.
Despite the considerable amount of research dealing with the study and development of force models during
milling, most of them, including those discussed above, consider the components of the cutting force at milling only
for the contour-cutting machining. At the same time, the peculiar features of 3D processing with a shaping tool are
ignored. Thus, they ignore the change in the thickness of the cut layer along the nonlinear cutting edge, the
displacement and change of the value of the tool-to-work contact along the cutting edge during one cutting cycle,
the dependence of the cutting force on the slope angle of the work to the cutter’s axis during processing, and other
factors connected with the complex tool movement of 3D milling. Therefore, such dependencies cannot be used
even for an approximate evaluation of the cutting forces in processing spatially-complex surfaces.
The force dependencies are based on one of the principally different methods: empirical, semi-analytical, or
analytical.
Empirical force dependencies approximated by polynomial equations have an individual nature, whereas the
exponents consider particular (narrow-range) experiment conditions based on equalization factors and values. The
use of these equations for practical calculations is marginal, as reliable production results can be obtained only for
conditions close to those in which the experiments were completed. Besides, when milling spatially-complex
surfaces, the presence of a wide variability range of numerous, interconnected factors influencing the cutting forces
considerably complicates obtaining empirical dependencies. An analysis of literature sources has shown that due to
said drawbacks the merely-empirical approach to deriving force dependencies for the 3D milling process has found
almost no application.
The semi-analytical approach is based on the development of generalized force dependencies with experimental
determination of the specific cutting force acting on the surface element of the tool blade. Thus, for the case of
milling spatially-complex surfaces with end-milling radial cutters, it was suggested by B.I. Frenkel and A.I. Travin
[11, 12] to determine the main component of the cutting force Pzi acting on a surface element by the following
equation:

P zi = fi × p (1)

In turn, the radial component Pri is taken in regard to the main component of the cutting force:

P ri = k×P zi (2)
 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49 45
4 V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000

Equation (1) makes an attempt to consider the variability of the value of the cutting edge-to-work contact in 3D
milling through the instant area of the cut layer fi. However, it does not consider the influence of the position of the
cutting edge’s active part on the cutting forces, as the author uses a constant specific force in the entire area of the
cross section of the cut. We know that the specific force depends on many cutting parameters (thickness of the cut,
value of the blunting area of the cutting edge, etc.) and changes along the cutter’s radial blade [13–16].
P. Meier studied the variance of the cutting force average value occurring at one length unit of the cutting edge at
line-by-line milling of a semi-cylinder [16]. Three different angles χ characterizing the position of the elementary
working (active) sections of the cutting edge on the cutter’s radial part being studied. From [16] is clear, that near
the cutter axis the maximum force occurring at one length unit of the blade’s active part is approximately 2.5 times
greater than that at the processing of a horizontal section and variable for different values χ.
Considering the variability of the specific force along the curvilinear blade of the end-milling radial cutter, V.M.
Svinin [15] introduces a equation to calculate the main component of the cutting force Pzi acting on the surface
element of the cutting edge in his work:

P zi = 1.155P× C × a
1+xa
×V xv - a ( P - σ o ) (3)

In turn, the full force Pz is determined by a summation of elementary forces Pzi along the active part of the cutting
edge. The radial-axial component of the cutting force Pxy is determined from the correlation:

P xy = η×P z (4)

Equations (3) and (4) contain the empirical coefficients obtained for the individual experimental conditions and
do not consider the kinematics of the 3D milling process. They also do not reflect the connection of the cutting
forces with such variable geometrical parameters of the cutting area as thickness of the cut layer, the position and
length of the active part of the cutting edge, which mainly depend on the direction of feed motion in space and the
slope angle of the work surface to the cutter axis. Therefore, they do not make it possible to set common regularities
of force variation when processing spatially complex surfaces. Besides, the above equations do not consider the
influence of the variability of the wear value along the radial cutting edge on the cutting force components.
A.I. Travin [11], K.I. Palk, N.G. Perelomov and V.M. Svinin [14] use the empirical proportionality coefficient,
the average values of which vary within the range of 0.5…0.8 to determine the cutting force components. However,
it is noted in the work of S.N. Egorov [13] that when calculating the cutting force components the use of the average
values of proportionality coefficients of these components can result in a gross error. In order to obtain explicit data
on the influence of some processing parameters on the cutting force components, S.N. Egorov [13] obtained the
following empirical dependencies:

Px 0.8ϕ 0.255 × lb0.048 Py 0.8lb0.063

= 0.101 0.058 - 1, = -1 (5)
Pz αc × γ c Pz V 0.051 × ϕ 0.304 × α c0.104

The dependencies (5) consider only the influence of the cutter’s geometry on the correlation of the cutting force
components. The absence of a connection between the forces and the physical and mechanical properties of the
work material, the slope angles of the work surface to the cutter axis, the geometrical parameters of the cutting area,
and the strictly empirical approach to obtaining of these equations point at their narrow applicability.
Thus, the empirical and semi-analytical dependencies have an individual nature, do not reflect physical processes
running at 3D milling, and do not fully disclose the reasons for changes to the cutting force components. Besides,
these dependencies do not consider the “downward” processing pattern, when a bridge between the teeth in the
center of the end-milling radial cutter takes part in cutting. The presence of empirical coefficients in the force
dependencies does not allow for full coverage of the whole variety of the processing patterns and cases of
interaction between the end-milling radial cutter and the work involved in 3D milling.
All these drawbacks can be eliminated in the analytical dependencies reflecting peculiar features of multivariant
processing conditions within the entire variability range of the variables influencing the cutting forces.
46 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49
V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000 5

3. Developing of a Multivariant Force Model

The processing of spatially complex surfaces is connected to continuous change of the geometrical parameters of
the cutting area (thickness of the cut, position and length of the active part of the cutting edge). At the same time,
different points of the curvilinear cutting edge become active and remove a different metal volume. In addition, the
chip formation process runs at variable speeds of the main cutting motion, the current values of which are
determined by the following correlation:

Vi = Vmax × sinϕi , (6)

Besides, due to the unequal speed, path length and other cutting conditions, there is an unequal wear along the
cutter blade. In such conditions, the specific cutting force (the force occuring at a unit of the blade length) along the
cutting edge on the sphere will be variable, wherein its variation is not proportional to the variation of the area of the
cut layer. Therefore, for analytical calculation of the cutting forces it is expedient to consider the cutting edge not as
a continuous curve but as a sequence of points with dissimilar geometrical parameters and cutting conditions.
When the cutter’s radial part is used, the resulting cutting force R acting at angle φ on a surface element with the
cutting edge length dL can be resolved into components dPx, dPy and dPxy (Fig. 1):

Fig. 1. Cutting force components acting on the surface element of the curvilinear cutting edge

Cutting force components can be determined using a procedure based on the fundamental law of mechanics concerning
the balance of active (external) and reactive (internal) forces (cutting forces and work metal resistance forces) and the
main laws of the plastic theory.
Major hydrostatic pressure (uniform compression) stresses which do not cause considerable plastic deformation
(the law of volume invariability) and gradually turn (with removal from their formation centers) into elastic stresses
and deformations, also decreasing with the removal from the plastic deformation area, appear in the volumes
adjacent to the plastically deformable area and have no free surfaces for the stresses' realization into plastic
deformations. The stress circle between directions τS and σN provides for the distribution of the stresses which occur
as a result of the plastic metal flow within line OA (Fig. 2).

Fig. 2. Flow pattern of forces and stresses on the tool’s face and back surfaces
 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49 47
6 V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000

The presence of normal stresses is a compulsory condition which prepares and ensures a share in the direction of
OA. The action of the tool’s face surface, on the one hand, and the presence of a support from the normal stresses
(below line OA), on the other hand, ensure the metal plastic flow in the direction of OA. At the same time, the value
of shear stresses τS and the normal stress consumed for the shear σN is most reliably determined via stress intensity
σi, the value of which, in turn, is determined by the properties of a particular material to maintain a particular
resistance to major plastic flow deformations (related to cutting) via the value of deformations ε, their speed έ and
the temperature T of the deformed metal. The position of line ОА (angle β1) also considers chip friction against the
face surface, whereas angle β1 is determined by the chip thickening coefficient already affected by the force of the
chip friction against the face surface.
According to the flow pattern of forces and stresses on the tool’s face and back surfaces (Fig. 2), shear force PS
and normal force PN, acting along the direction of ОА and perpendicular to line ОА, are calculated accordingly:

a× dL σi a× dL
PS = ⋅ , PN = × σi (7)
sinβ1 3 sinβ1

Considering (7), the resultant force of plastic deformation of the cut layer is determined by the expression

2 2
 σ × a× dL   σi × a× dL  1.15a× dL× σi
Rc =  i  +   = (8)
 sinβ1   3 × sinβ1  sinβ1

The angle between the shear line and the direction of the resulting force Rc is related to the shear angle β1. For a
wide range of the cutting conditions present when processing with the cutter’s radial part, angle β can be determined
from the following correlation [17]:

β = ( 50 - β1 ) 0.8 (9)

The resulting force Rc and angle β are used to determine the cutting force components – Pzc. The components Pxc
and Pyc are determined considering the position of the surface element on the curvilinear part of the cutting edge:

Pxc = ( 1.15a× dL× σ i ) sinβ1 × sinβ × cosϕ

Pyc = ( 1.15a× dL× σ i ) sinβ1 × sinβ × sinϕ (10)
Pzc = ( 1.15a× dL× σ i ) sinβ1 × cosβ

In the real process the cutter tooth has wear area lb, to determine the forces it is necessary to consider elastic
deformations and the friction against the back surface. Due to the firm adherence of area ОВ (Fig. 2) to the work
metal, there are no conditions under the area for the sharp release of normal stresses arising at the plastic metal
deformation and covering the area between the shear line and the contour of the stress circle. Therefore, there is a
rough assumption that normal stresses subside along the length of the friction area in point О to zero in point В. The
integration of the function of normal stress distribution on the contact area gives an average stress value 0.252σi
[18]. Then, force Pxy(fr), counterbalancing the stresses along line ОВ, and the force of metal friction against the back
surface Pz(fr) is determined as follows:

Pxy(fr) = 0.252σ i ×lb × dL, Pz(fr) = 0.252 µ × σ i ×lb× dL (11)

Considering that the length of the surface element of the cutter’s cutting edge is dL=R×dφ, the components of the
cutting force acting on the cutter tooth are obtained by summation of the elementary components along the active
part of the cutting edge:
48 V. A.Victor
BatuevA. et
Batuev et al. / Procedia
al. / Procedia Manufacturing
Manufacturing 32000–000
00 (2018) (2019) 42–49 7

ϕu ϕu
a
Pz = 1.15σ i ∫ × cosβ × R× dϕ + 0.252 µ × σ i ∫ lb × R× dϕ
ϕl sinβ1 ϕl
ϕu ϕu
a
Px = 1.15σ i ∫ × sinβ × cosϕ × R× dϕ + 0.252 µ × σ i ∫ lb × cosϕ × R× dϕ
ϕl sinβ1 ϕl (12)
ϕu ϕu
a
Py = 1.15σ i ∫ × sinβ × sinϕ × R× dϕ + 0.252 µ × σ i ∫ lb × sinϕ × R× dϕ
ϕl sinβ1 ϕl

Then, the thickness of the cut is determined by the expression:

2
a = 1- ( sinϕ × sinψ × sinω + cosϕ × cosω ) - sin 2ϕ × cos 2ψ (13)

Model (12) sets the functional interconnection between the cutting force components in each moment of the tooth
turn and the elements of the cutting modes, the slope angle of the work surface and its configuration expressed via
the position and the length of the active part of the cutting edge, the physical and mechanical properties of the work
material, and the degree of the tooth wear. The above analytical force dependencies also allow us to consider the
variable chip formation conditions (thickness of the cut, cutting speed, etc.) along the curvilinear cutting edge.

4. Experimental study

Experimental studies aimed at checking the adequacy of the analytical dependencies of the cutting forces when
milling spatially complex surfaces have shown that the difference between the calculated and experimental values of
the force does not exceed 10 %, which confirms the accuracy of the developed calculation equations. Figure 3
shows graphs of the dependence of the cutting force components on the slope angle of the work surface at an instant
value of the tooth turn angle ψ=90°. These graphs show the values of forces obtained experimentally when
processing steel 45 with a two-tooth cutter with the spherical part radius r=8 mm, feed per tooth S z=0.1 mm/tooth,
and milling width b=2 mm. Operation was carried out without cooling. The cutting force was measured by Kistler
dynamometer.
The research findings show that at various slope angles of the work surface, the correlation of the cutting force
components vary within wide ranges exceeding the manifold the data of the empirical dependencies, which confirms
the narrow authenticity range of the latter.

Fig. 3. Dependence of the cutting force components Px, Py, Pz on the slope angle of the work surface ω, at ψ=90º.
● – experimental values of the force components.
 Victor A. Batuev et al. / Procedia Manufacturing 32 (2019) 42–49 49
8 V. A. Batuev et al. / Procedia Manufacturing 00 (2018) 000–000

Thus, only analytical dependencies for the calculation of the cutting forces which consider the influence of all the
factors in a wide variability range of variables can be used for analysis and control of 3D milling of spatially-
complex surfaces on CNC machines.

5. Conclusion

Empirical and semi-analytical dependencies have an individual nature, do not reflect physical processes running
during 3D milling, and do not fully disclose the causes for changes to the cutting force components. The presence of
empirical coefficients in these force dependencies does not allow for full coverage of the whole variety of the
processing patterns and cases of interaction between the end-milling radial cutter and the workpiece.
The analytical dependencies of cutting force were developed. These dependencies set the functional
interconnection between the components in each moment of the tooth turn (via angle ψ), elements of the cutting
modes, the slope angle of the work surface (via angle ω) and its configuration expressed through the length and
position of the active part of the cutting edge (via angles φ u, φl), the stress intensity in the moving volume of the
deformed material (σi), and the value of the cutter teeth blunting area (lb). In addition, the developed analytical force
dependencies allow for the consideration of variable chip formation conditions (thickness of cut а, cutting speed V,
etc.) along the curvilinear cutting edge. The developed system of dependences allows to predict the cutting forces
and controlling the process while designing.

Acknowledgements

South Ural State University is grateful for financial support of the Ministry of Education and Science of the
Russian Federation (grant No 9.5589.2017/8.9).

References

[1] J. Feng, Zh. Tao, Y Lan, Analytical model of milling forces based on time-variant sculptured shear surface, International Journal of
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