Mechanistic modeling of cutting forces in end milling with the direct cutting edge

Prediction of cutting forces by analytical modeling methods in the machining process has a considerable importance. In this study, mechanistic modeling was used to predict cutting forces in milling process by two-cutting edge end mill tool with a straight cutting edge κ = 90°. This modeling approach due to no need for costly experiments to obtain material behavior information in the high strain rate cutting process and due to no need for time-consuming analysis by numerical software as well as the application of material characteristics and cutting conditions with coefficients of cutting and cutting edge have acceptable performance and accuracy. In this research, for the first time, a special design for the work piece was considered to eliminate the effect of round insert tip on modeling error. The results of comparing the predicted and experimental cutting force curves obtained from the dynamometer for the three cutting force components〖 F〗_x, F_yand F_z show acceptable agreement.〖 F〗_x, F_yand F_z show acceptable agreement.