A force model of face milling tool considering wear

The objective of this paper is to construct a three-dimensional oblique cutting force model for a single-tooth face-milling tool with a chamfered main cutting edge incorporating a wear factor. The research has been carried out to determine the behavior of medium carbon steel plate, S45C, during milling processes dry conditions. The effects of different types of tool geometry and the secondary chip are observed. The variations of shear plane areas occurring in the tool-worn situation are also used. Cutting experiments are conducted on S45C carbon steel plate, and the experimental data correlates closely with the theoretical values. SEM analysis has been carried out on the worn tools to determine the tools wear surfaces. A preliminary discussion is also made for the design of special tool holders and their geometrical configurations. Next, the sharp tips mounting in the tool holders are ground to a wear depth, and the worn tool dimensions are measured by using a toolmaker microscope.