Cutting force modelling for peripheral milling with a disk cutter considering the instantaneously engaged area

Peripheral milling process with a disc milling cutter can be used for the manufacture of freeform surface. In this paper, a cutting force model for this milling process is proposed considering instantaneously engaged area. Firstly, the peripheral milling process with the cutter is described. Secondly, the geometrical and mathematical models of the cutting tools and chip are modelled. To obtain instantaneous cutting forces, three related geometrical parameters including the instantaneous cutting thickness, instantaneously engaged height of right-side edge and instantaneously engaged area are defined and solved. Then the cutting force model is established with the cutting force coefficients solved using the data from cutting tests. Finally, series of cutting experiments are performed on H59 brass to verify the effectiveness of the proposed analytical model. The errors in the predicted result are within 5.97%, 8.06% and 16.14% in the x, y and z directions.