Mechanistic modeling of cutting forces in milling process by end milling with cutting edges with adjustment angle of 45 degree

Determination of machining forces in order to calculate the required power and torque for cutting and select the right tools, equipment, and cutting parameters (feed rate, cutting depth, cutting speed) for machining the desired geometry and material prior to the process is significant. The analysis of machining forces is necessary to determine the forces to reduce the cost of performing multiple empirical experiments. In this study, the components of, , and  milling forces with two cutting edges with main adjustment angle were predicted by the mechanistic modeling method by calculating cutting and edge force coefficients. Also, for the first time, the cutting section of the workpiece was designed in order to eliminate the calculating error of the round corner of inserts.To avoid the interaction of the parameters, simultaneous change of cutting speed with feed rate was avoided and 8 experiments with different feed rates but with the same cutting speed were performed. A comparison of the modeled forces curve with the results obtained from the dynamometer shows acceptable agreement.As the feed rate increases, the difference between the predictive and experimental force decreases relative to the increase of force.