A hybrid approach for cutting force prediction in flank milling based on analytical and 3D finite element method

Flank milling is one of the most widely used milling processes characterized by high machining efficiency. However, due to the low thermal conductivity and high-temperature strength of nickel-based superalloy Inconel 718, flank milling of Inconel 718 is still an extremely difficult and challenging task in which the milling cutter suffers large cutting force and excessive tool wear. Therefore, prediction of cutting force in milling process has caused due attention and became a major concern in manufacturing process. The present work is thus aimed at developing a new cutting force model for flank milling, which might try to eliminate the drawbacks of pure analytical force model, data-based reasoning method (DBRM), and full three dimensional (3D) finite elements (FE) model. The hybrid cutting force model is conducted by discretizing cutting edge into fragments based on infinitesimal method and regarding each fragment as a 3D oblique cutting FEM model. With the integration of 3D predicted cutting force along the axis considering the run-in and run-out effect of each cutting edge, the predicted cutting force can be obtained. Finally, the predicted results showed a good agreement with that of experimental.