A Mechanistic Model for End Milling Cutting Forces in Brittle Porous Material

Abstract:

A mechanistic model capable of predicting end milling cutting forces in brittle porous media is described. A coefficient which is capable of reproducing the random shape and variation in cutting forces due to porosity is proposed. In addition, a method of experimental determination of cutting force coefficients is outlined. The proposed model is based on the hypothesis that the random shape and variation in cutting forces of brittle porous media coincide with the shape and variation of pore size and distribution in the media. The developed coefficient and model is compared to end milling tests conducted in CB1100, a porous machinable alumina based ceramic manufactured by UMECO. High correlation between predicted and measured cutting forces is shown. Experiments show that the model is capable of accurate prediction of variation in individual cutting tooth force profile shape and overall magnitude over the entire range of machining conditions tested. The benefit of the model lies in its ability to greatly reduce the number of cutting tests required when investigating cutting forces in novel brittle porous materials.

• Periodical: Advanced Materials Research (Volume 1082)
• Pages: 143-151
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.1082.143
• Online since: December 2014
• Authors: Alex O’Connor, Mamidala Ramulu*
• Keywords: Brittle Materials, Ceramic, Cutting Force Model, Milling, Porosity

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