An improved cutting force prediction model in the milling process with a multi-blade face milling cutter based on FEM and NURBS

Multi-blade face milling cutters are widely used in the finish machining of mechanical parts. The cutting force in the milling process is a crucial factor that promotes the chatter of the machine spindles, which can be used to predict the machined surface roughness. In this paper, a novel cutting force prediction model based on non-uniform rational basis splines (NURBS) and finite element method (FEM) is proposed. Single blade cutting forces under different parameters are simulated by FEM, and a cutting force model of the single blade is established by the NURBS interpolation method. Then, combined with the tool tip motion model, the cutting force of the multi-blade face milling cutter can be predicted. To verify the correctness of the cutting force predicted by the proposed method, the common coefficient-based cutting force mathematical prediction method is utilized as benchmark for comparison with the predicted results. The accuracy is verified by comparison with experimental data. According to the collected experimental data, the proposed model is proved to be an accurate and efficient method to predict the cutting force of the multi-blade face milling cutter in the milling process.