Well a good place to learn quite a LOT is in this book it pretty much is the Bible for the machining world.
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
Well a good place to learn quite a LOT is in this book it pretty much is the Bible for the machining world.
try this , it should give you a general idea of the cutting force http://metalworking.com/Shareware/machine_design.zip
A poet knows no boundary yet he is bound to the boundaries of ones own mind !! ........
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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
call me interested...If anyone is interested I can give details about it.
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
great information....
thanks for posting it.