Modelling of static and dynamic milling forces in inclined operations with circle-segment end mills

Circle-segment mills are new solid end mills with oval profiles that begin to substitute ball end-mills in some applications. They are intended for high performance finishing of complex surfaces in 5-axis operations. This work deals with the mechanical characterization of such tools. A time domain model is proposed to predict tool's cutting behavior in static and dynamic conditions. The influence of tool geometry, orientation tilt and lead angles, modal parameters and cutting conditions was modeled. As a result, an accurate method is presented to predict forces and vibrations in inclined milling operations. This can be very useful to avoid vibrations during the last steps in the manufacturing of blisk and impellers that may harm the workpiece quality. Theoretical simulations against experimental data are provided to validate the approach for this new tool concept.