Int J Adv Manuf Technol (2017) 90:1003–1022
DOI 10.1007/s00170-016-9418-2
ORIGINAL ARTICLE
Modeling and analyses of helical milling process
Yanling Tian 1,2 & Yunpeng Liu 1 & Fujun Wang 1 & Xiubing Jing 1 & Dawei Zhang 1 &
Xianping Liu 2
Received: 5 June 2016 / Accepted: 29 August 2016 / Published online: 16 September 2016
# Springer-Verlag London 2016
Abstract A comparison between the geometry of the helical
milling specialized tool and conventional end mill was firstly
introduced. Furthermore, a mathematical model, in which the
cutting area was divided into different cutting zones, was
established to simulate the cutting depths and volume of the
different cutting edges (three kinds) on specialized tool.
Accordingly, a specific ratio between the volume removed
by different edges and the total hole volume was derived
mathematically and modeled using 3D modeling software
SolidWorks. Based on the established models, the cutting
depths and cutting volume ratio variation trends under differ-
ent cutting parameters were analyzed. The results showed that
the change rules of cutting depths were different in every
cutting zone and influenced greatly by the cutting parameters.
In addition, the cutting volume ratio changes with different
cutting parameters, but it can only vary in a certain range
due to the structure of the helical milling specialized tool.
The cutting volume ratio obtained from the established model
shows a good agreement with the data modeled using
SolidWorks, proving that the established model is appropriate.
Moreover, the undeformed chip geometry was modeled and
observed using SolidWorks. The undeformed chip showed a
varying geometry with different cutting parameters, and it can
be optimized to obtain a good cutting condition during helical
milling process.
* Fujun Wang
wangfujun@tju.edu.cn
1
Key Laboratory of Mechanism Theory and Equipment Design of
Ministry of Education, Tianjin University, Tianjin 300072, China
2
School of Engineering, University of Warwick, Coventry, CV4
7AL, UK
Keywords Helical milling . Cutting depth . Cutting volume .
Cutting ratio . Chip morphology
1 Introduction
In modern aircraft manufacturing process, thousands of
holes need to be made to meet the complex assembly re-
quirements. As an alternative to conventional drilling, the
helical milling technique offers many advantages. It pos-
sesses a better heat dissipation condition, which can reduce
the thermal damage on both the machined surface and the
milling tool and thus improve hole quality and increase the
working life of the milling tool [1–4]. An improvement in
geometrical accuracy, a reduction in burr formation, and a
smaller cutting force are observed when the helical milling
method is compared with the drilling method [5–7].
Another advantage of helical milling is that it can make
different diameter holes only using one tool, which signif-
icantly improves the processing efficiency [8].
Recently, a number of research efforts have been directed
toward helical milling in the aspects of the influences of cut-
ting parameters on cutting force, cutting temperature, tool
wear, and quality of the machined surface [9–12]. However,
the variation of cutting parameters directly affects the cutting
depth, cutting volume, and undeformed chip morphology, and
then the changes of these indexes lead to the variation of
cutting force, cutting temperature, and so on [13–14].
Therefore, it is necessary to build a mathematical model to
describe the relationships between the cutting depth, cutting
volume, and cutting parameters and have a fundamental re-
search on the change regulations of undeformed chip geome-
try under varying cutting parameters.
Brinksmeier et al. [15] described mathematically the cut-
ting depths of periphery and front cutting edges of
1004 Int J Adv Manuf Technol (2017) 90:1003–1022

conventional end mill; the ratio between periphery cutting

volume and front cutting volume was also discussed. Based
Periphery
on chip-splitting principle and the tool’s movement feature, Periphery
cutting
Liu et al. [16] designed a new specialized tool for helical edge cutting
milling with distributed multi-point front cutting edge and edge
modeled the undeformed chip morphology using 3D model-
ing software; the material removal rates for the conventional
end mill and helical milling specialized tool were also obtain-
ed using 3D modeling software. Denkena et al. [17] modeled
the undeformed chip geometry for helical milling, in which Outside edge Inside edge
Front cutting edge
the axial depth of cut of periphery cutting edges is assumed to
(a) (b)
increase approximately linearly with the tool rotation angle,
and used it to explain the impact of the axial and tangential Fig. 1 Structure of two different helical milling tools: a conventional end
mill; b helical milling specialized tool
feed per tooth on the process forces. Li et al. [18] described the
cutting depths and undeformed chip geometry of conventional
end mill, then proposed a novel dynamic cutting force model
from the tool axis is called the outside front cutting edge
for helical milling. Chen et al. [19] presented a new dynamic
(outside edge), and the part near the tool axis is called the
cutting force model with nominal chip thickness for predicting
inside front cutting edge (inside edge). This special struc-
the stability of interrupted turning, wherein the dynamical
ture makes it participate in a discontinuous cutting and
cutting force was defined by a function of nominal chip thick-
produce discontinued chips.
ness and dynamical chip thickness. Liu et al. [20] proposed an
Helical milling is composed of three movements: rota-
analytical model to accurately predict the cutting forces and
tion about the tool axis (spindle rotation), rotation about
torque during helical milling operations as a function of heli-
the axis of the machined hole (revolution), and linear mo-
cal feed, spindle velocity, axial and radial cutting depth, and
tion along with the axis direction of the machined hole
milling tool geometry.
(Fig. 2). The circumferential feed and axial feed are pro-
The cutting depth is essential during the cutting force
vided respectively by revolution and linear motion of the
modeling, and the cutting volume ratio can reflect contribu-
tool. It is convenient to change the machining diameter of
tion of different cutting edges during the material removing
the hole by varying the eccentricity (e) between the axis
process. The undeformed chip geometry is useful for the pre-
of the tool and the axis of the hole. Different cutting
diction of cutting force and surface quality [21]. However,
edges produce different types of cutting force. When
there are no reports on the theoretical calculation method of
adopting different cutting parameters, the volume of the
cutting depths and cutting volume for the helical milling spe-
material removed by the periphery cutting edge and the
cialized tool. There is also little information available in liter-
front cutting edge will change and lead to the variation of
ature about change rules of undeformed chip geometry of the
cutting force components in axial and radial directions.
specialized tool under different cutting parameters so far.
Therefore, the material removal rate is also a parameter
Therefore, it is necessary to establish the models for the cut-
worthy of further study.
ting depth and cutting volume of the helical milling special-
ized tool; investigate the effects of the helical course (ap) and
eccentricity (e) on the cutting depths, cutting volume, volume
Axis of the
ratio, and undeformed chip geometry based on the established
cutting tool
models; and obtain the change regulations of the undeformed
Ot
chip geometry.
Axial feed Axis of the
machined hole
2 Helical milling process

In helical milling process, a strong interaction will happen Bore hole Revolution
between tool and workpiece [22]. Thus, high performance
is demanded for the milling tool. The structures of con-
Oh
ventional end mill and helical milling specialized tools are
shown in Fig. 1. Different from the structure of conven-
tional end mill, the front cutting edge of the helical mill- Workpiece
ing specialized tool is composed of two parts: the part far Fig. 2 Kinematics of helical milling
Int J Adv Manuf Technol (2017) 90:1003–1022 1005

Direction of feed
3 Cutting depths of periphery cutting edge,
inside edge, and outside edge Tool
Cut by periphery
In helical milling process, all cutting edges are involved edge
directly, and cutting states vary with different cutting pa-
rameters. In order to observe and analyze the cutting A B
depths, the machined surface is modeled with Funnel-shaped
SolidWorks. Figure 3 shows the geometrical conditions cavity Cut by inside edge Cut by outside edge
between the tool and workpiece; there are three cutting Fig. 4 Schematic drawing of material removal process
zones in helical milling process: the periphery cutting
zone, the outside cutting zone, and the inside cutting ap Depth setting of the helical course
zone. h1i Cutting depth of periphery edge
Figure 4 shows the cutting states of periphery cutting h2i Cutting depth of inside edge
edge, inside edge, and outside edge. In the cutting pro- h3i Cutting depth of outside edge
cess, the outside edge will contact with the workpiece and Ri Arbitrary inspection radius
cut off a part of the material first. A funnel-shaped cavity e Eccentricity
will generate under the inside edge when the tool rotates
around its axis due to the inclination of the inside edge,
and the material in the cavity will be removed by the The value of depth setting of the helical course (ap) has a
inside edge. The material remaining between the two or- significant influence on cutting depths. With the increase in
bital periods that outside and inside edges cannot remove ap, the cutting depths of all kinds of cutting edges increase
will be cut by the periphery cutting edge. gradually, and the uncut material under the tool shows differ-
For calculation simplification, a projection plane through ent morphologies. To some extent, the morphology of the
the tool axis (Fig. 5a) is built and the endpoints of cutting uncut material formed by the tool can reflect the variation
edges on one cutter tooth are revolved around the tool axis trend of the cutting depths. By observing the 3D models
to the projection plane. Figure 5b shows the graph of cutting formed using SolidWorks, it is noted that there are four types
edges on the projection plane. Rm is the distance from the of morphology when ap changes from small to large (Fig. 6).
lowest point C′ on the front cutting edge to the tool axis; θ1 In the first type, the helicoid is divided into three regions when
and θ2 are angles between the projection lines of the cutting ap is small enough. In the second type, the helicoid is divided
edges and the horizontal plane. into four regions when the value of ap exceeds the threshold
In order to further investigate the cutting stages of the cut- value ap1. In the third type, the helicoid is divided into three
ting edges and determine the periphery cutting depth (h1i), regions when ap exceeds the threshold value ap2. In the last
inside cutting depth (h2i), and outside cutting depth (h3i), the type, the helicoid contains only one region when ap exceeds
variable Ri (arbitrary inspection radius) is also introduced to the threshold value ap3.
help find the relationships between cutting depths (h1i, h2i, h3i) Through the observation of the uncut material morphology,
and parameters (Rh, Rt, Rm, ap, θ1, e) [15]. the conclusion can be obtained that the cutting depth of the
For the calculation, the following variables are used: periphery cutting edge can always be reduced to zero within
the limits of 0 ∼ π. In different regions, the change rules for
Rh Hole radius
cutting depths are various. In the following sections, the com-
Rt Tool radius
putational method of cutting depths in different kinds of uncut
material morphology is discussed.
Periphery cutting zone Outside cutting zone
Workpiece Projection
A'
plane
Tool
Rt

Rm
Projection
A drawing D'
B'
θ2 θ1
B C D C'
Horizontal plane

Inside cutting zone (a) (b)

Fig. 3 Three cutting zones between tool and workpiece during helical Fig. 5 Projection of the helical milling specialized tool: a projection
milling process diagram; b graph of cutting edges on the projection plane
1006 Int J Adv Manuf Technol (2017) 90:1003–1022

Fig. 6 Four types of uncut

material morphology: a the first
type; b the second type; c the third
type; d the fourth type

(a) (b) (c) (d)

3.1 Cutting depth of periphery cutting edge
3.1.1 The first type of uncut material morphology
(condition 1)
In this condition, the helicoid is divided into three regions
shown in Fig. 7a. It can be seen that the width of region 1 is
very small when compared with the widths of regions 2 and 3.
Region 1 is formed by the periphery cutting edge; region 2 is
formed by the outside cutting edge; region 3 is formed by the
inside cutting edge. Figure 7b shows the second type of uncut
material morphology. Four regions can be seen in condition 2.
When compared with Fig. 7a, regions 1, 2, and 3 in two
conditions are the same, but region 4 only appears in condition
2. Region 4 is also formed by the periphery cutting edge.
In Fig. 8, with the value of ap increasing, the chip formed
by the periphery cutting edge may come into being in different
regions, and there are four possible status: (a) only in region 1,
(b) in regions 1 and 2, (c) in regions 1, 2, and 3 but not
reaching maximum, and (d) reaching maximum.
In regions 1, 2, and 3, the calculation methods of the pe-
riphery cutting depth (h1i) are uniform in conditions 1 and 2.
Therefore, the derivation of the periphery cutting depth (h1i) in
condition 1 is not listed here.
3.1.2 The second type of uncut material morphology
(condition 2)
In this condition, the helicoid is divided into four regions, and
the cutting trajectory of the periphery cutting edge from points
A to E is also divided into four segments (Fig. 9). The change
rules of the periphery cutting depth (h1i) are different in every
region. The variation of the cutting depth of the periphery
cutting edge can be divided into two parts: one part comes
from the decrease along the radial direction and another part
comes from the decrease along the circumferential direction.
In order to show the different change rate between the two
parts in every region, the variable r is introduced. The radiuses
of boundaries between different regions are denoted by R1, R2,
and R3.
Region 1: As shown in Fig. 10, the periphery cutting edge
cuts into the material in point A and moves along in a clock-
wise direction. When the periphery cutting edge moves to
point K, the decrease along the circumferential direction can
be calculated using angle βi and the decrease along the radial
direction can be replaced by the decrease along the circumfer-
ential direction from K to K′ (corresponding to angle θ4i).
According to the geometrical relationship in Fig. 10, it is noted
that θ4i = βi. Therefore, the decrease of the cutting depth along
the radial direction (h1211i) is equal to the decrease along the
circumferential direction (h1212i) in region 1, and the follow-
ing equations can be obtained.
θ4i
h1211i ¼ ap ⋅ ð1Þ
2π
βi
h1212i ¼ ap ⋅ ð2Þ
2π
Figure 10 shows the geometrical relationships for angle βi.
According to the law of cosines, the following equation can be
derived.

2 
Ri þ e2 −R2t
βi ¼ arccos ð3Þ
2eRi

Fig. 7 Regional division of the Region 1

uncut material: a three regions in
condition 1; b four regions in
condition 2
Region 2
Region 1

Region 2 Region 3

Region 3
Region 4

(a) (b)
Int J Adv Manuf Technol (2017) 90:1003–1022 1007

Chip of peripheral Chip of peripheral Chip of peripheral Chip of peripheral

cutting edge Region 1 cutting edge Region 1 cutting edge Region 1 cutting edge Region 1
Region 2 Region 2 Region 2 Region 2
B
B
B B
A Oh A Oh A Oh A Oh

Region 3 Region 3 Region 3 Region 3

(a) (b) (c) (d)

Fig. 8 Periphery cutting chips generated in different regions: a region 1; b regions 1 and 2; c region 1, 2, and 3; d reaching maximum

Since θ4i = βi, substituting Eq. (3) into Eqs. (1) and (2) The ratio between the decrease along the radial di-
gives rection and the decrease along the circumferential direc-

2  tion in region 1 (r21) can be expressed as Eq. (10).
ap Ri þ e2 −R2t
h1211i ¼ arccos ð4Þ
2π 2eRi h1211i
r21 ¼ ⇒r21 ¼ 1 ð10Þ

2  h1212i
ap Ri þ e2 −R2t
h1212i ¼ ⋅ arccos ð5Þ
2π 2eRi
Equation (10) shows that the decrease along the circumfer-
ential direction and the radial direction in region 1 is always
When Ri = R1, h1211i and h1212i reach maximum. the same.

2 
ap R1 þ e2 −R2t Region 2: As shown in Fig. 11, the tool mark in
h1211max ¼ arccos ð6Þ
2π 2eR1 region 2 is formed by the outside edge. The direction

2  of the tool mark is not along the radial direction but has
ap R1 þ e2 −R2t
h1212max ¼ ⋅ arccos ð7Þ an included angle γ. Point J is the intersection of radius
2π 2eR1 Ri and the tool mark. L3 is the distance from point J to
center Ot. Equation (11) can be developed according to
Once h1211i and h1212i are known, the cutting depth the law of cosines and geometrical relationships in tri-
of the periphery cutting edge in region 1 can be obtain- angle JOhOt.
ed.
h1i ¼ ap −h1211i −h1212i ð8Þ R2i ¼ e2 þ L23 −2eL3 cosðπ−γ Þ ð11Þ

Substituting Eqs. (4) and (5) into Eq. (8) gives

2  Taking the root of Eq. (11),
1 R þ e2 −R2t
h1i ¼ ap 1− arccos i ð9Þ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
π 2eRi
L3 ¼ R2i −e2 sin2 γ −ecosγ ð12Þ

B'
Region 1
C' Region 2
B C K'

R1 R2 D D'

E
A R3
Rh
B
Rh
E' K
Region 3 Ri
Rt
θ4i
Region 4 αi e βi
A Ot Oh
Fig. 9 Four segments of the cutting trajectory of the periphery cutting
edge in condition 2 Fig. 10 Graphic for the calculation of h1i in region 1
1008 Int J Adv Manuf Technol (2017) 90:1003–1022

When Ri = R2, h1221i and h1222i reach maximum.

!
ap R2 þ R22 −ðRt −Rm Þ2
I h1221max ¼ ðRt −Rm Þtanθ1 − arccos 1
2π 2R1 R2
R1 J
θ5i ð17Þ
Ri
e γ L3
2 
Oh Ot ap R þ e2 −R2t
h1222max ¼ arccos 2 ð18Þ
Rt 2π 2eR2

Once h1221i and h1222i are known, the cutting depth of the
periphery cutting edge in region 2 can be obtained.
h1i ¼ ap −h1211max −h1221i −h1222i ð19Þ

Fig. 11 Schematic diagram for the calculation of L3 and θ5i

The ratio between the decrease along the radial direction
and the decrease along the circumferential direction in region
The angle θ5i can be obtained according to the geometrical 2 (r22) can be expressed as Eq. (20).
relationships in triangle IJOh and the law of cosines.
! r22 ¼
h1221i
ð20Þ
R21 þ R2i −ðRt −L3 Þ2 h1222i −h1212max
θ5i ¼ arccos ð13Þ
2R1 Ri
Substituting Eqs. (7), (15), and (16) into Eq. (20) gives
Once L3 and θ5 are obtained, the decrease along the radial !
direction from B to K (h1221i) can also be obtained (Fig. 12). 2π R21 þ R2i −ðRt −L3 Þ2
ðRt −L3 Þtanθ1 −arccos
ap 2R1 Ri
θ5i r22 ¼
2  ð21Þ
h1221i ¼ ðRt −L3 Þtanθ1 −ap ⋅ ð14Þ 2
2
2π Ri þ e −Rt
2
R1 þ e2 −R2t
arccos −arccos
2eRi 2eR1

Substituting Eq. (13) into Eq. (14) gives

Region 3: In Fig. 13, the point Om is the center of the circle
!
ap R21 þ R2i −ðRt −L3 Þ2 corresponding arc KK’. The decrease along the radial direction
h1221i ¼ ðRt −L3 Þtanθ1 − arccos ð15Þ can be replaced by the decrease along the circumferential di-
2π 2R1 Ri
rection from K to K′ (corresponding to angle θ6i).
Equation (22) can be developed according to the geomet-
The decrease along the circumferential direction from A to
rical relationships in triangle KOmOh.
K (h1222i) can be obtained.

2 

2  Ri þ e2 −R2m
ap R þ e2 −R2t θ6i þ θ7i ¼ arccos ð22Þ
h1222i ¼ arccos i ð16Þ 2eRi
2π 2eRi

K'

K' C Rm
K K
C D Om
B R2
Ri Rt Ri θ
7i
R1 θ6i e
Rt θ5i
e βi
αi βi Ot Oh
e
Ot Oh
Fig. 13 Graphic for the calculation of periphery cutting depth h1i in
Fig. 12 Graphic for the calculation of h1i in region 2 region 3
Int J Adv Manuf Technol (2017) 90:1003–1022 1009

According to the geometrical relationships in triangle direction can be replaced by the decrease along the cir-
K’OmOh, the angle θ7i can be obtained: cumferential direction from K to K′ (corresponding to

2  angle θ8i). According to the geometrical relationship, it
R þ e2 −R2m
θ7i ¼ arccos 2 ð23Þ is easy to know θ8i = θ9i. Therefore, the decrease of the
2eR2
cutting depth along the radial direction is equal to the
Thus, substituting Eq. (23) into Eq. (22) gives decrease along the circumferential direction in region 4.

2 
2  The decrease along the radial direction from D to K (h1241i)
Ri þ e2 −R2m R2 þ e2 −R2m
θ6i ¼ arccos −arccos ð24Þ can be expressed as follows.
2eRi 2eR2
θ8i
h1241i ¼ ap ð33Þ
After angle θ6i is deduced, the decrease along the radial 2π
direction from C to K (h1231i) can be obtained.
According to the geometrical relationships in Fig. 14, angle
θ6i θ8i can be calculated.
h1231i ¼ ap ⋅ ð25Þ
2π
2 
2 
Ri þ e2 −R2t R3 þ e2 −R2t
θ8i ¼ arccos −arccos ð34Þ
Substituting Eq. (24) into Eq. (25) gives 2eRi 2eR3

2 
2 
ap Ri þ e2 −R2m R2 þ e2 −R2m
h1231i ¼ arccos −arccos Substituting Eq. (34) into Eq. (33) gives
2π 2eRi 2eR2 
2 
2 
ð26Þ ap e þ R2i −R2t e þ R23 −R2t
h1241i ¼ arccos −arccos
2π 2eRi 2eR3
The decrease along the circumferential direction from A to ð35Þ
K (h1232i) can be expressed as the following.

2  The decrease along the circumferential direction from A to
ap R þ e2 −R2t
h1232i ¼ arccos i ð27Þ K (h1242i) can be obtained.
2π 2eRi
2 
ap e þ R2i −R2t
h1242i ¼ arccos ð36Þ
When Ri = R3, h1231i and h1232i reach maximum. 2π 2eRi

2 
2 
ap R þ e2 −R2m R þ e2 −R2m
h1231max ¼ arccos 3 −arccos 2 Once h1241i and h1242i are known, the periphery cutting
2π 2eR3 2eR2
depth in region 4 can be obtained.
ð28Þ

2  h1i ¼ ap −h1211max −h1221max −h1231max −h1241i −h1242i ð37Þ
ap R3 þ e2 −R2t
h1232max ¼ arccos ð29Þ
2π 2eR3
The ratio between the decrease along the radial direction
and the decrease along the circumferential direction in region
Once h1231i and h1232i are known, the cutting depth of the
4 can be expressed as Eq. (38).
periphery cutting edge in region 3 can be obtained.
h1241i
h1i ¼ ap −h1211max −h1221max −h1231i −h1232i ð30Þ r24 ¼ ⇒r24 ¼ 1 ð38Þ
h1242i −h1232max
The ratio between the decrease along the radial direction
and the decrease along the circumferential direction in region
3 can be expressed as Eq. (31).
D
h1231i
r23 ¼ ð31Þ
h1232i −h1222max R3 K
Rt K'
θ9i Ri
Substituting Eqs. (18), (26), and (27) into Eq. (31) gives βi θ8i

2 
2  e
R þ e2 −R2m R þ e2 −R2m Ot Oh E
arccos i −arccos 2
2eRi 2eR2
r23 ¼
2 
2  ð32Þ
Ri þ e2 −R2t R2 þ e2 −R2t
arccos −arccos
2eRi 2eR2
E'
Region 4: Figure 14 shows the graphic for the calcu- Fig. 14 Graphic for the calculation of the inside cutting depth h1i in
lation of h1i in region 4. The decrease along the radial region 4
1010 Int J Adv Manuf Technol (2017) 90:1003–1022

Therefore, the cutting depth of the periphery cutting edge The feed angle of per tooth (ε) around the hole axis can be
in different regions of condition 2 can be expressed as follows: calculated as the following.
8
>
> ¼ ap −h1211i −h1212i ; Ri∈½R1 ; Rh  2πng
< ε¼ ð43Þ
¼ ap −h1211max −h1221i −h1222i ; Ri ∈½R2 ; R1  nz N
h1i ¼
>
> ¼ ap −h1211max −h1221max −h1231i −h1232i ; Ri ∈½R3 ; R2 
:
¼ ap −h1211max −h1221max −h1231max −h1241i −h1242i ; Ri ∈½Rt −e; R3  According to the geometrical relationships in Fig. 15, angle
ð39Þ ε can also be expressed as Eq. (44).

2 
2 
However, Eq. (39) requires the value of R1, R2, R3, and γ. R1 þ e2 −R2t R1 þ e2 −R2a
ε ¼ arccos −arccos ð44Þ
As shown in Fig. 15, the large blue circle is the trajectory of 2eR1 2eR1
the highest point on the outside cutting edge rotating around
the axis of the tool and the small blue circle of radius Ra is the Let Eq. (43) equals to Eq. (44).
trajectory of the point which is a feed per tooth lower along the
2 
2 
2πng R1 þ e2 −R2t R1 þ e2 −R2a
axial direction of the hole than the highest point on the outside ¼ arccos −arccos ð45Þ
nz N 2eR1 2eR1
edge. The red dotted circle is the position of the big blue circle
rotating around the hole axis about a feed angle of per tooth
around the hole axis. The intersection of the small blue circle Equation (45) contains only variable R1 and ap, but it is a
and the red dotted circle, which is far from the center Oh, is transcendental equation which is unable to obtain the analyt-
marked N, and the value of Ri is equal to the distance between ical solution. Assuming that R1 is expressed by ap with the
point Oh and point N. following equation,
The feed per tooth along the axial direction can be calcu-  
R1 ¼ f ap ð46Þ
lated by Eq. (40).
a p ⋅ ng
f za ¼ ð40Þ Equation (47) can be developed according to the geomet-
N nz
rical relationships in triangle MOhOt (Fig. 15).
where ng is the revolution speed, nz is the spindle speed, and N R21 ¼ R2a þ e2 −2eRa cosðπ−γ Þ ð47Þ
is the number of tool tooth.
Furthermore, the radius of the small blue circle (Ra) can be Rewriting Eq. (47),
obtained.
2 
R þ e2 −R21
f za γ ¼ arccos a ð48Þ
Ra ¼ Rt − ð41Þ −2eRa
tanθ1
When Ri = R2, the value of L3 calculated by Eq. (12) is
Substituting Eq. (40) into Eq. (41) gives
exactly Rm. Therefore, R2 can be calculated according to the
a p ⋅ ng geometrical relationships in triangle JOhOt (Fig. 16).
Ra ¼ Rt − ð42Þ
N nz tanθ1 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
R2 ¼ ðe þ Rm cosγ Þ2 þ ðRm sinγ Þ2 ð49Þ

M
I
N
R1 Rt R1 J
Ra θ5i
ε
e γ e R2 γ Rm
Oh Ot Oh Ot
Rt

Fig. 15 Schematic diagram for the calculation of radius R1 and angle γ Fig. 16 Graphic for the calculation of radius R2
Int J Adv Manuf Technol (2017) 90:1003–1022 1011

As shown in Fig. 17a, the altitude intercept between The distance between center Om1 and Om2 can be calculat-
points E’ and H is equal to the height of the outside ed when the angle θ10 is known.
cutting edge. The decrease of the periphery cutting pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
depth from F to G can be calculated using angle θ10. LOm2 Om1 ¼ e ⋅ 2ð1−cosθ10 Þ ð54Þ
In addition, points E’ and F are at the same height, and
points H and G are also at the same height. Figure 17b Furthermore, the angle θ13 can be calculated because the
shows the geometrical relationship between the parame- three sides of the triangle Om2E’Om1 are known.
ters used in calculation of R3.
!
Therefore, the following equation can be obtained. 2e2 ð1−cosθ10 Þ þ R2t −R2m
θ13 ¼ arccos pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð55Þ
θ10 2eRt 2ð1−cosθ10 Þ
ðRt −Rm Þ ⋅ tanθ1 ¼ ap ⋅ ð50Þ
2π
Rewriting Eq. (50), Substituting Eq. (55) into Eq. (53) gives
!
2πðRt −Rm Þtanθ1 π−θ10 2e2 ð1−cosθ10 Þ þ R2t −R2m
θ10 ¼ ð51Þ θ12 ¼ −arccos pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð56Þ
ap 2 2eRt 2ð1−cosθ10 Þ
The angle from position 1 to position 2 (θ11) can be
expressed as Eq. (52). R3 can be calculated according to the geometrical relation-
ships in triangle EOhOm1 and the law of cosines.
2πðRt −Rm Þtanθ1
θ11 ¼ θ10 ⇒θ11 ¼ ð52Þ vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u !!
ap u π−θ10 2e2 ð1−cosθ10 Þ þ R2t −R2m
R3 ¼ tR2t þ e2 −2eRt cos −arccos pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2eRt 2ð1−cosθ10 Þ
In isosceles triangle Om2OhOm1, the length of OhOm1 is
equal to the length of OhOm2 and Eq. (53) can be derived. ð57Þ
π−θ10
θ12 þ θ13 ¼ ð53Þ Substituting Eq. (51) into Eq. (57) gives
2

vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
0 0
11
u

u 2π ð R −R Þtanθ
u B B 2e2 1−cos t m 1
þ R2t −R2m CC
u B π πðRt −Rm Þtanθ1 B CC
u 2 a
R3 ¼ uRt þ e −2eRt cosB −arccosB CC
p
2
B − B sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

 CC ð58Þ
u @2 ap @ pffiffiffi 2πðRt −Rm Þtanθ1 AA
t 2 2eRt 1−cos
ap

Fig. 17 Graphic for the y

calculation of radius R3: a
morphology of the uncut material; Position 2
θ10
b calculation chart F

R 2 om2
E' F E' G
Rh
H
R3 θ
H θ11 θ12 13 Rm
Oh Oh e O m1 x
G Rt

Position 1

(a) (b)
1012 Int J Adv Manuf Technol (2017) 90:1003–1022

ap1 is the boundary value for morphology of the uncut B' Region 1
material from condition 1 to condition 2. Assuming that re-
gion 4 exists, the value R3 can be calculated. However, region B C' C Region 2
4 is very small and is cut by the outside cutting edge, so region
4 cannot be seen in condition 1. With the increase of value ap, R3
R1
the value of R3 also increase. When R3 reaches Rt-e, the value
of ap is the boundary value ap1. e D
A Ot Oh
Substituting R3 = Rt-e into Eq. (58), the value ap1 can be
calculated. However, the explicit solution of ap1 cannot be Rh
derived because Eq. (58) is a transcendental equation.
Assume that ap1 is expressed as the following. D'

ap1 ¼ f 2 ðRt ; Rm ; Rh Þ ð59Þ Region 4

ap2 is the boundary value for morphology of the uncut

Fig. 19 Regional division of the uncut material in condition 3
material from condition 2 to condition 3. When circles Om
and Ot are in interior contact (Fig. 18), the value of ap is the
calculation method of the cutting depth is similar to condition
maximum that can be sustained in condition 2. In this case, the
2, and the analysis and calculating process is not repeated
minimum of angle θ10 can be obtained.
here.
!
2e2 −ðRt −Rm Þ2 3.1.4 The fourth type of uncut material morphology
θ10min ¼ arccos ð60Þ (condition 4)
2e2

Substituting Eq. (60) into Eq. (51) gives In this condition, the helicoid contains only one region
(Fig. 20). Therefore, the periphery cutting depth is easy to
2πðRt −Rm Þtanθ1 calculate and can be expressed as the following.
ap2 ¼ ! ð61Þ
2e2 −ðRt −Rm Þ2
arccos
2e2 
2 
1 e þ R2i −R2t
h14i ¼ ap 1− arccos ; Ri ∈½Rt −e; Rh  ð62Þ
π 2eRi

3.1.3 The third type of uncut material morphology

(condition 3) 3.2 Cutting depth of inside cutting edge

In this condition, the helicoid is divided into three regions and The cutting depth of the inside edge (h2i) is easier to calculate
region 3 disappears compared to condition 2 (Fig. 19). The than the cutting depth of the periphery cutting edge (h1i). As

y K' Region 1
Position 2
θ10mi n K Rh

Ri
Rh Om2 Rt
e B
Oh O m1 x A Ot Oh
Rt

Position 1

Fig. 18 Schematic diagram for the calculation of boundary value ap2 Fig. 20 Regional division of the uncut material in condition 4
Int J Adv Manuf Technol (2017) 90:1003–1022 1013

mentioned above, the formula of the periphery cutting depth Equation (68) describes the relationship between the cut-
varies when the morphology of the uncut material changes. ting depth of the inside edge (h2i) and the depth setting of the
However, the calculation method of the inside cutting depth helical course (ap). The value of h2i changes lineally with ap.
remains unchanged no matter what the morphology of the
uncut material is.
3.3 Cutting depth of outside cutting edge
The cutting depth of the inside edge (h2i) can be developed
with the projected tool path triangle on the arbitrary inspection
As shown in Fig. 22, the uncut material is divided into four
radius Ri (Fig. 21) [15].
zones according to the kinds of cutting edges participating in
h2i ap U mi the milling process. In zone 1, the periphery cutting edge and
¼ ⇒h2i ¼ ap ⋅ ð63Þ
U mi U Ri U Ri the outside edge participate in the cutting process together
(Fig. 23a). In zone 2, the three kinds of cutting edges all
participate in the milling process (Fig. 23b). In zone 3, the
Equation (63) describes the geometric dependence of the outside cutting edge and the inside cutting edge participate
inside cutting depth (h2i) on the arc length of the full circle in the milling process together (Fig. 23c). In zone 4, only the
with radius Ri, the depth setting per orbital path (ap), and the outside cutting edge participates in the milling process
inspection arc (Umi). The value of Umi and URi can be (Fig. 23d).
expressed as follows. Assuming that h1i and h2i are known, the cutting depth of
the outside edge (h3i) can be calculated with the following
U mi ¼ 2θ14i Ri ð64Þ
equation.
U Ri ¼ 2πRi ð65Þ 8
>
> ap −h1i ; Ri ∈½e þ Rm ; Rh 
<
Substituting Eqs. (64) and (65) into Eq. (63) gives ap −h1i −h2i ; Ri ∈½Rt −e; e þ Rm 
h3i ¼ ð69Þ
>
> a p −h2i ; Ri ∈½e−Rm ; Rt −e
θ14i :
h2i ¼ ap ⋅ ð66Þ ap ; Ri ∈½0; e−Rm 
π

According to the geometrical relationships in triangle

BOhOt and combined with the law of cosines, the angle θ14i
4 Effects of the depth setting of the helical course (ap)
can be derived.

2  and eccentricity (e) on cutting depths (h1i, h2i, h3i)
R þ e2 −R2m
θ14i ¼ arccos i ð67Þ
2eRi The morphology of the uncut material may be different with
varying cutting parameters. To some extent, it also reflects the
Substituting Eq. (67) into Eq. (66) gives variation of the cutting depths. The effects of depth setting of

2  the helical course (ap) on morphology of the uncut material
ap Ri þ e2 −R2m have been mentioned above (Fig. 6); four kinds of morphol-
h2i ¼ arccos ð68Þ
π 2eRi ogies will appear with the increase of ap. The impact of

Fig. 21 Graphic for the

calculation of the inside cutting
depth h2i: a morphology of the
uncut material; b calculation URi
B
Hole diamater Dh

diagram
Inspection arc Umi

Ri
B Ri Rm θ14i
Ot e Oh
Oh
A
A

Tool diamater Dt

(a) (b)
1014
Peripheral cutting chip Zone 1
Zone 2
C
Rh
Rm e+R m
A Rt e (e = 2, e = 1, e = 0.5), it can be found that the width of interval
Zone 3
Zone 4
Fig. 22 Area partition of the uncut material according to the participating
edges
eccentricity (e) on morphology of the uncut material is shown
in Fig. 24. When the value of ap is kept unchanged, the mor-
phology of the uncut material changes with the increase of
eccentricity (e) from a small value to a large value.
Furthermore, the morphology formed by the tool belongs to
the four kinds of morphology mentioned above. Therefore,
the calculation methods of cutting depths (h1i, h2i, h3i) are also
useful. In order to find out the relationships between the cut-
ting depths (h1i, h2i, h3i) and the cutting parameters (ap, e), the
calculation of cutting depths was made with constant cutting
parameters in Table 1.
The effects of the depth setting of the helical course (ap)
and eccentricity (e) on the periphery cutting depth (h1i) are
given in Fig. 25. The red, green, blue, and black curves show
the variation of the periphery cutting depth with Ri under
different morphology of the uncut material respectively (con-
ditions 1, 2, 3, and 4). As shown in Fig. 25a, when the eccen-
tricity (e) is kept constant, it can be seen that the change in rule
of h1i is a little different with various ap. When ap is small, the
h1i decreases with the decrease of Ri at an almost constant
change rate in the right part of the curve and at a smaller
constant change rate in the left part. It is also noteworthy that
the value of Ri corresponding to h1i = 0 decreases with the
increase of ap, which means that the length of the periphery
cutting chip increases with the increase of ap. When ap is
large, h1i decreases sharply with a gradually reductive change
Tool Tool
h1i
h1i h3i
ap
h3i h2i
(a) (b)
Fig. 23 Type of cutting edges in different zones: a zone 1; b zone 2; c zone 3; d zone 4
Int J Adv Manuf Technol (2017) 90:1003–1022
rate when the value of Ri decreases in the right part of the
curve. However, in the middle part of the curve, h1i decreases
almost linearly. Then, the change rate increases rapidly with
the decrease of Ri at the left part of the curve. It also can be
observed that the third type of morphology of the uncut ma-
terial appears only in a very narrow interval of ap. When
comparing the change rules of h1i with different value of e
of ap, in which the second type of morphology appears, de-
creases gradually (see Fig. 25b) and becomes zero (see
Fig. 25c) at some point with the value of e reducing. The
fourth type of morphology will appear at a lower value of ap
with the decrease of e.
The effects of the depth setting of the helical course
(ap) and eccentricity (e) on the inside cutting depth (h2i)
are also provided based on the established models.
Figure 26a shows the influence of ap on the inside cut-
ting depth when e takes a large value. It can be seen that
h2i increases with the increase of ap. h2i on both ends of
curves is zero and sharply increases from the ends to the
middle part of curves. The maximum of h2i appears near
Ri = 1, which is not in the middle of curves. This phe-
nomenon is caused by two reasons: one reason is that the
change rate of the cutting depth along the circumferential
direction (ap/2πRi) increases gradually when Ri changes
from Rh to 0; the other reason is that the length of the
inspection arc U mi first increases and then decreases
when Ri changes from Rh to 0. Figure 26c shows the
influence of ap on the inside cutting depth when e takes
a small value. It can be seen that h2i increases signifi-
cantly till reaching maximum and keeps unchanged when
Ri changes from a large value to zero. When comparing
the change in rules of h2i with different values of e
(e = 2, e = 1, e = 0.5), it can be found that the cutting
area of the inside edge decreases with the decrease of e,
and the material near the center of the hole will be re-
moved completely by the inside edge when e takes a
small value. Therefore, h2i equals to the value of ap in
the area near the center of the hole.
Figure 27 shows the curves of the outside cutting depth
(h3i) with different values of ap and e. The curves of h3i are
a little complex when compared with the curves of h1i and h2i.
When e is kept constant, h3i changes gently with a small value
of ap and the change rate of h3i increases with the increase of
Tool Tool
h3i
ap ap h3i ap
h2i
(c) (d)
Int J Adv Manuf Technol (2017) 90:1003–1022 1015

Fig. 24 Morphology of the uncut

material under different
eccentricity e (ap = 0.4 mm/r): a
e = 0.5; b e = 1; c e = 2 mm

(a) (b) (c)

ap. When comparing the change in law of h3i with different
values of e (e = 2, e = 1, e = 0.5), it can be found that the curve
pattern varies significantly; one reason is that the cutting area
of the cutting edges changes with the variation of e.
5.2 Cutting volume of the inside edge
On the thin wall cylinder of radius Ri, the cutting area of the
inside edge in one orbital revolution can be expressed as the
following.

A2i ¼ 2π ⋅ Ri ⋅ h2i ð72Þ

5 Cutting volume and cutting volume ratio
The inside edge participates in cutting in the range of Ri∈[e-
Rm, e + Rm]; the volume removed by the inside edge (V2) is
The changes of cut volume of the cutting edges will influence
given by the summation of all partial areas over the radius
the cutting conditions such as chattering, variation of the cut-
Ri∈[e-Rm, e + Rm]. The cut volume V2 in one orbital revolution
ting forces, and the deformation degree of the cutting tool.
can be obtained by integrating A2i in the range of [e-Rm, e +
Therefore, the cut volumes of the periphery cutting edge
Rm].
(V1), the inside cutting edge (V2), and the outside cutting edge
(V3) are calculated respectively and then the cut volume ratios Z eþRm
are derived. V 2 ¼ 2π h2i ⋅ Ri ⋅ dRi ð73Þ
e−Rm

5.1 Cutting volume of the periphery cutting edge

5.3 Cutting volume of the outside edge
On the thin wall cylinder of radius Ri, the cutting area of the
periphery cutting edge in one orbital revolution can be The direct solution of the cut volume of the outside edge (V3)
expressed as the following. is a little complicated. Therefore, it is obtained by subtracting
the volume removed by the periphery cutting edge (V1) and
A1i ¼ 2π ⋅ Ri ⋅ h1i ð70Þ
the inside edge (V2) from the total volume removed by all
cutting edges (V) in one orbital revolution.
Assuming that the periphery cutting edge participates The cut volume Vand V3 can be expressed as the following:
in cutting in the range of Ri∈[R0, Rh], the volume re-
moved by the periphery cutting edge (V1) is given by V ¼ π ⋅ R2h ⋅ ap ð74Þ
the summation of all partial areas over the radius V 3 ¼ V−V 1 −V 2 ð75Þ
Ri∈[R0, Rh]. The cut volume V1 in one orbital revolution
can be obtained by integrating A1i in the range of Ri Substituting Eqs. (71), (73), and (74) into Eq. (75) gives
∈[R0, Rh]. Z Rh Z eþRm
Z V 3 ¼ π ⋅R2h ⋅ ap −2π h1i ⋅ Ri ⋅ dRi −2π h2i ⋅ Ri ⋅ dRi
Rh
R0 e−Rm
V 1 ¼ 2π h1i ⋅ Ri ⋅ dRi ð71Þ
R0 ð76Þ

Figure 28 shows the impact of ap on cutting volumes V1,

Table 1 Cutting parameters and tool structure V2, and V3. When ap changes from 0.1 to 2.2 mm/r, V1 in-
creases almost linearly as a whole, the change rate of V1 is a
Rt (mm) Rm (mm) θ1 (°) N nz (r/min) ng (r/min) little lower when ap is small than ap is large. V2 changes
3 1.76 8.32 4 25.64 1500
linearly with ap, and this result can also be deduced from
Eqs. (68) and (73). When ap changes from small to large, V3
1016 Int J Adv Manuf Technol (2017) 90:1003–1022

Fig. 25 Variation of periphery ap=2.2 ap=1.6

ap=2
cutting depth h1i under different

Periphery cut depth h1i/(mm)

ap=1.4

Periphery cut depth h1i/(mm)

ap=1.83
ap and e: a e = 2; b e = 1; c ap=1.7 ap=1.2
e = 0.5 mm ap=1.5
ap=1
ap=1.3
ap=0.85
ap=1.1
ap=0.7
ap=0.9
ap=0.7 ap=0.5
ap=0.5
ap=0.3
ap=0.3
ap=0.1
ap=0.1

Arbitrary inspection radius Ri/(mm) Arbitrary inspection radius Ri/(mm)

(a) (b)

ap=1
Periphery cut depth h1i/(mm)

ap=0.9

ap=0.8
ap=0.7

ap=0.6

ap=0.45

ap=0.3

ap=0.2

ap=0.1

Arbitrary inspection radius Ri/(mm)

(c)

Fig. 26 Variation of the inside ap=2.2 ap=1.6

ap=2
cutting depth h2i under different ap=1.4
ap=1.83
ap and e: a e = 2; b e = 1; c
Inside cut depth h2i/(mm)

ap=1.7
Inside cut depth h2i/(mm)

ap=1.2
e = 0.5 mm ap=1.5
ap=1
ap=1.3
ap=1.1 ap=0.85

ap=0.9 ap=0.7

ap=0.7 ap=0.5
ap=0.5
ap=0.3
ap=0.3
ap=0.1 ap=0.1

Arbitrary inspection radius Ri/(mm) Arbitrary inspection radius Ri/(mm)

(a) (b)

ap=1
ap=0.9
ap=0.8
Inside cut depth h2i/(mm)

ap=0.7

ap=0.6

ap=0.45

ap=0.3

ap=0.2

ap=0.1

Arbitrary inspection radius Ri/(mm)

(c)
Int J Adv Manuf Technol (2017) 90:1003–1022 1017

Fig. 27 Variation of the outside

cutting depth h3i under different

Outside cut depth h3i/(mm)

ap and e: a e = 2; b e = 1; c

Outside cut depth h3i/(mm)

e = 0.5 mm ap=1.6
ap=2.2
ap=2 ap=1.4
ap=1.83
ap=1.7 ap=1.2
ap=1.5 ap=0.7 ap=1
ap=1.3
ap=0.85
ap=1.1 ap=0.5
ap=0.9
ap=0.7 ap=0.3
ap=0.5
ap=0.3 ap=0.1
ap=0.1

Arbitrary inspection radius Ri/(mm) Arbitrary inspection radius Ri/(mm)

(a) (b)

ap=1

ap=0.9
Outside cut depth h3i/(mm)

ap=0.8
ap=0.7

ap=0.6

ap=0.45

ap=0.3
ap=0.2
ap=0.1

Arbitrary inspection radius Ri/(mm)

(c)

Fig. 28 Variation of the cut

Cut volume of periphery edge V1/(mm3)

volume under different depth

Cut volume of inside edge V2/(mm3)

setting of the helical course ap

(e = 2 mm): a V1; b V2; c V3

Depth setting of the helical course ap/(mm/r) Depth setting of the helical course ap/(mm/r)

(a) (b)
Cut volume of outside edge V3/(mm3)

Depth setting of the helical course ap/(mm/r)

(c)
1018 Int J Adv Manuf Technol (2017) 90:1003–1022

e=2
e=2
e=1
e=1
e=0.5
e=0.5
deflection of the tool and cause vibration, and the axial cutting
Calculating data force may make the workpiece deform in the axial direction of
Measured value
the machining hole and lead to poor surface integrity.
The ratio G

The ratio G can reflect the distribution of the cutting forces

along the radial direction and the circumferential direction to
some extent. Therefore, it is necessary to study the influence
of the parameters on the ratio G between periphery cut volume
(V1) and front cut volume (V–V1). The ratio G can be calcu-
lated as follows.

Depth setting of the helical course ap/(mm/r)

V1
G¼ ð77Þ
Fig. 29 Variation of the ratio G under different ap and e
V−V 1

increases with a large rate first and then increases with a small- Figure 29 shows the impact of the depth setting of the
er rate when ap reaches beyond a critical value. (Fig. 28c). helical course (ap) and eccentricity (e) on the ratio G. It
can be seen that the calculated ratio G is in good agree-
ment with that of measured in SolidWorks. The slight
5.4 The ratio (G) between periphery cutting volume difference may be due to the modeling error in
and front cutting volume SolidWorks and the approximate calculation in MatLab.
When e is kept unchanged and ap takes a small value,
In helical milling process, the different cutting edges will pro- the ratio G is very low, which indicates that most of the
duce different types of cutting force. The periphery cutting hole volume is removed by the inside and outside cutting
edge produces mainly radial cutting force; the front cutting edges. With a p increasing, the ratio G increases and
edge produces not only radial cutting force but also axial cut- reaches maximum when ap exceeds a certain threshold,
ting force. The radial cutting force may lead to radial which means that the ratio G can only change in a limited

Fig. 30 Variation trends of G1,

Calculating data G1 G2 G3 Calculating data G1 G2 G3
G2, and G3 under different ap and Measured value G1 G2 G3 Measured value G1 G2 G3
e: a e = 2; b e = 1; c e = 0.5 mm
Percentage/(%)

Percentage/(%)

Depth setting of the helical course ap/(mm/r) Depth setting of the helical course ap/(mm/r)

(a) (b)

Calculating data G1 G2 G3
Measured value G1 G2 G3
Percentage/(%)

Depth setting of the helical course ap/(mm/r)

(c)
Int J Adv Manuf Technol (2017) 90:1003–1022 1019

Chip of the periphery Chip of the outside 5.5 The ratio (G1, G2, G3) between the cutting volume
cutting edge edge of cutting edges and the total hole volume

All cutting edges are directly involved in helical milling process,

and a strong interaction will happen between tool and workpiece.
The cutting edges will wear gradually with the cut volume in-
creasing. Tool failure occurs once the wear condition of any edge
reaches the critical value. However, some edges wear sharply,
Chip of the inside edge Connection part but some edges wear slightly in helical milling process, which
may lead to varying degrees of wear on different edges.
Fig. 31 Undeformed chip geometry formed by helical milling
specialized tool Therefore, it is essential to find out the ratio between the
volume removed by the periphery cutting edge and the total hole
volume (G1), the ratio between the volume removed by the inside
range and cannot increase without limit. When e takes edge and the total hole volume (G2), and the ratio between the
values of 2, 1, and 0.5, the maximum values of ratio G volume removed by the outside edge and the total hole volume
are 1.78, 0.78, and 0.36, respectively. It can be seen that (G3). The ratio G1, G2, and G3 can be calculated as follows.
the maximum of ratio G decreases when e changes from
V1
small to large. The change interval of ratio G becomes G1 ¼ ð78Þ
V
smaller with the decrease of e. It is remarkable that the
V2
maximum of ratio G equals to the ratio between the pe- G2 ¼ ð79Þ
riphery and front cut volume removed by conventional V
end mill over one orbital revolution. V3
G3 ¼ ð80Þ
V

Fig. 32 Variation of undeformed chip geometry under different ap (e = 2 mm)

1020
Fig. 33 Variation of undeformed chip geometry under different eccentricity e (ap = 0.1 mm/r)
Simulations under different cutting parameters were
carried out to reveal the impact of the depth setting of
the helical course (ap) and eccentricity (e) on the ratio
G1, G2, and G3, and the results were shown in Fig. 30.
It can be seen that the calculated ratios G1, G2, and G3
are in good agreement with that of measured in
SolidWorks.
As shown in Fig. 30a, it is easy to be found that the
ratio G1 increases remarkably with the increase of ap and
reaches maximum when ap reaches beyond some certain
value. The ratio G2 stays constant no matter what value
of the ap is. The ratio G3 decreases with ap changing
from small to large and reaches minimum when a p
reaches beyond some certain value. When the curves of
ratio G1, G2, G3 with different values of e are compared,
it can be found that the maximum of ratio G1 decreases
gradually with the decrease of e. However, the value of
ratio G2 and the minimum of ratio G3 increase with the
decrease of e. When e takes a large value (Fig. 30a, b),
the volume removed by the outside edge is larger than
the volume removed by the periphery cutting edge with a
small value of ap and smaller than the volume removed
by the periphery cutting edge with a large value of ap.
Int J Adv Manuf Technol (2017) 90:1003–1022
When e takes a small value (Fig. 30c), the volume re-
moved by the outside cutting edge is always larger than
the volume removed by the periphery cutting edge no
matter what value of ap is.
6 Undeformed chip geometry during helical milling
processes
In actual manufacturing process, the undeformed chip geom-
etry is an indicator which should be treated carefully. On the
one hand, it can reflect the working intensity of the different
parts on the cutting edge and evaluate the wear rate of the
cutting edge. On the other hand, the size of the undeformed
chip will influence the degree of difficulty of chip removal.
The machined surface may be scratched when the size of the
undeformed chip is large, which will reduce the quality of the
machined surface. In addition, the deformation degree of the
cutting chip changes with different morphology of the cutting
chip and a too-large deformation degree will lead to unfavor-
able situations, such as the increase of power dissipation and
cutting force. Therefore, it is necessary to study the
Int J Adv Manuf Technol (2017) 90:1003–1022
relationships between the morphology of the undeformed chip
and the cutting parameters.
The undeformed chip geometry of the helical milling spe-
cialized tool is shown in Fig. 31. Three kinds of chip can be
seen in the picture: the chip formed by the periphery cutting
edge has a small width and height but a large length (part in
blue); the chip formed by the outside cutting edge has a small
height but a large width and length, which looks like a fan.
Similar to the morphology of the chip formed by outside edge,
the geometry of the inside cutting chip also looks like a fan,
but the size of it is smaller than the former. It can also be found
that the connection between the chips of the inside edge and
the outside edge is weak, which will break easily and facilitate
chip removal effectively.
The impact of the depth setting of the helical course
(ap) on the undeformed chip geometry is given in Fig. 32.
The width of the undeformed periphery chip stays the
same, but the length and height increase sharply when
ap changes from a small value to a large one; the maxi-
mum that the length can reach is πRt. The width, length,
and width of the undeformed inside chip increase with the
increase of ap, but the length-width ratio decreases. As for
the undeformed outside chip, the length of it increases
slowly with ap increasing. When ap takes a small value,
the width of a part of the chip reaches maximum and the
width of the last part is still small. The proportion of the
part where the width reaches maximum increases when ap
takes a larger value. From Fig. 32, it can also be found
that the length of the connection between the chips of the
inside edge and the outside edge becomes larger and larg-
er, which may lead to a difficulty in separating.
The influence of the eccentricity (e) on the undeformed
chip geometry is given in Fig. 33. The length of the periphery
chip decreases when e changes from small to large; the width
and height keep unchanged. The length and width of the in-
side chip decrease and the length-width ratio increases with
the increase of e. When e = 0.5 and e = 1, the width of the right
part of the inside chip is larger than the width of the left part
obviously. One reason is that the material in the middle of the
hole is removed by the inside cutting edge completely. The
length of the outside chip decreases with the increase of e, and
the proportion of the part where the width reaches maximum
also decreases. It is also worth noting that the length of the
connection between the chips of the inside edge and the chip
of the outside edge becomes smaller and smaller, which im-
proves the chip removal condition.
The study on relationships between the undeformed chip
geometry and cutting parameters (ap and e) is profitable. It is
conducive to optimize machining parameters of helical mill-
ing and helpful to improve the tool life. The structure of the
tool has a significant influence on chip morphology.
Therefore, research on undeformed chip geometry is useful
for assisting in the design of the helical milling specialized
1021
tool and can make the structure more suitable for the helical
milling method.
7 Conclusions
This paper is focused on calculation method of cutting depths
(h1i, h2i, h3i), cut volumes (V, V1, V2, V3), and cut volume ratios
(G, G1, G2, G3), description of undeformed chip geometry for
helical milling specialized tool. The influence of the depth
setting of the helical course (ap) and eccentricity (e) on cutting
depths, cut volume, and cut volume ratios was also investigat-
ed. Based on the results of calculation and modeling using
SolidWorks, the following conclusions can be drawn:
1. The comparison between the structures of the conven-
tional end mill and helical milling specialized tool shows that
the specialized tool is more suitable in helical milling process.
2. The calculation methods of cutting depths vary with
different cutting parameters (ap and e). Four types of uncut
material morphology may appear, and the hole is divided into
regions, where the cutting depths change with different rules,
to calculate the cutting depths using different methods. The
change rate of cutting depths along the radial direction and the
circumferential direction is different.
3. The cut volumes (V, V1, V2, V3) increase with the increase
of ap and e. When ap is small, the change rates of the cut
volumes are different, V1 increases faster than V1 and V2, and
V2 increases faster than V3; the change rates of the cut volumes
are the same when ap reaches beyond some certain value.
4. When e is kept unchanged, the ratios (G, G1) increase
with the increase of ap and reach maximum after ap reaches
beyond some certain value; the ratio G2 keeps unchanged no
matter what the value of ap is; and the ratio G3 decreases with
the increase of ap and reaches minimum after ap reaches be-
yond some certain value. When ap is kept unchanged, the
ratios (G, G2, G3) increase with the increase of e, but the ratio
G1 decreases with the increase of e.
5. The changes of ap and e will affect the unchanged chip
geometry, and the chip geometry can be optimized by adjusting
the value of ap and e to obtain a good cutting condition.
Acknowledgments The research is supported by National Natural
Science foundation of China (No. 51420105007) and EU H2020
FabSurfWAR (No. 644971).
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