Geometrical model for rectangular-inserted face milling of surfaces with parabolic cross-sections in parallel direction with machining feed

Developments in face milling inserted cutters have considerably contributed to the efficiency of the process. In this article, a geometrical model for face milling of surfaces with parabolic cross-sections has been considered. These surfaces are produced by welding techniques for purposes such as retrieving lost geometry, improving wear and fatigue properties and implementation of rapid manufacturing concept. So as to obtain an integral flat surface, the produced layer has to be truncated. 0n the other hand, machining depth is not constant due to special cross-section of the weld beads. A precise model for definition of depth of cut in face milling of surfaces with parabolic cross-sections is presented owing to have the most important effect on machining forces. First, the parabolic cross-sections and rectangular inserted disc with 10 degree a8ial immersion were de9ined using mathematical relations. Ne8t, intersection curves were e8tracted and the related depths of cut were calculated. Finally, the depth of cut model was verified and the method to incorporate the results in the mechanistic force model was discussed. It is shown that the proposed method is very effective in finding the proper instantaneous depths of cut for use in the unified machining model.