Comprehensive Cutting Force Model for Milling Processes with Solid End Mills and Inserted Cutters

A generalized cutting mechanics model is proposed for milling processes with solid end mills and inserted cutters. The unified mathematical model is employed for the description of the solid milling flute and insert on a reference tool body. The friction and normal forces acting on the rake face are transformed into milling coordinates using a general transformation matrix by simply assigning operation specific parameters. The generalized model can be used to predict and optimize the machining operations including solid end mills and inserted cutters.