Linear and Nonlinear Model of Cutting Forces in Peripheral Milling: A Comparison Between 2D and 3D Models

Peripheral milling is extensively used in manufacturing processes, especially in aerospace industry where end mills are used for milling of wing parts and engine components. Knowledge of the cutting forces is the first necessary stage in analysis of the milling process. In this paper, cutting forces are presented for both two and three dimensional models. Instead of the common linear dependency of cutting forces to the cut chip thickness, two nonlinear models are presented. In the first model, cutting forces are considered as a function of chip thickness with a complete third order polynomial. In the second one, the quadratic and constant terms of the third order polynomial are set to zero. Results show about 2–3% and 2–7% maximum error between the linear, first and second nonlinear models, for 2D and 3D models, respectively. According to the simulation results, both the 2D and 3D models with second type of nonlinearity can be effectively used in practice. The advantage of such modelling is its simplicity in nonlinear analysis of the problem based on perturbation techniques.