Router design

[fnm]

I'm very much interested in router design and I should like to know the following details about it.
1- What are typical forces generated by a tool when milling aluminum? I mean x,y,z maximum levels of forces for milling aluminum.
2- Where I could find detailed technical information or data about this subject?
Anybody knows a good mechanical engineering handbook about milling?
Thank you in advanced for your help
-Francesc

[silentreaper]

Well a good place to learn quite a LOT is in this book it pretty much is the Bible for the machining world.

[dertsap]

try this , it should give you a general idea of the cutting force http://metalworking.com/Shareware/machine_design.zip

[fnm]

Originally Posted by dertsap try this , it should give you a general idea of the cutting force http://metalworking.com/Shareware/machine_design.zip

Thank you Dertsap for your information. This program by Jim Tuttle has been very useful for me because it is exactly what I wanted and it permits me to compare different data generated with cutting force models. However if someone is interested in prediction of cutting forces in aluminum end milling I would recommend to read the article:
"A comparison of analytical cutting force models" published by WIAS
where one can find very simple models to compute cutting forces during end milling aluminum as a function of chip thickness and axial depth of cut. If anyone is interested I can give details about it.
Now I can continue with my design
-Francesc

[Matt McColley]

If anyone is interested I can give details about it.

call me interested...

[fnm]

Originally Posted by Matt McColley call me interested...

Kinzle-Victor model for predicting end milling Aluminum cutting forces

Cutting forces, according Kinzle-Victor model, can be predicted through this formula Fi=Ki*a*h^(1-mi)
Where “Fi” is force in N, “a” is the load per tooth in (mm) , “h” is the depht of cut in (mm) and “Ki” and “ mi” are constants that depend of “h” values
The Kinzle-Victor model predicts tangential Ft and radial Fr milling cutting forces
For end milling aluminum the values of constants Ki and mi are:

Kr=39 for 0.001 < h <0.01 ; Kr=99 for 0.01 <= h <0.1 ; Kr=298 for 0.1 <= h <1
Kt=336 for .001 < h <.01; Kt=493 for 0.01 <= h <0.1 ; Kt=667 for 0.1 <= h <1
mr= 1 for 0.001 < h <0.01; mr=0.8 for 0.01 <= h <0.1; mr=0.32 for 0.1 <= h <1
mt= 0.53 for 0.001 < h <0.01 ; mt=0.45 for 0.01 <= h <0.1; mt=0.32 for 0.1<= h <1

For example for cutting depht of 0.5 mm and a load per tooth of 0.1 mm the forces for aluminum are:
Ft=Kt*a*h^(1-mt)=493*0.5*0.1^1-0.45=69 N
F=Kr*a*h^(1-mr)=99*0.5*0.1^1-0.8=31 N

Model computes tangential and radial forces located at xy plane but doesn’t compute axial force at z axis and I don’t know if are average or peak forces
Using Jim Tuttle program with the same conditions and a rake angle of 20º the force predicted is 26 lbs or 115 N. I don’t know if this 115 N force is the total force

[Matt McColley]

great information....

thanks for posting it.

[steve323]

Originally Posted by silentreaper Well a good place to learn quite a LOT is in this book it pretty much is the Bible for the machining world.

Also, if you might want to find the large print edition of the machinery handbook. It might be ~$20 more.

I find the standard size to be sort of small. A larger format would be easier to read.

Steve