Cutting dynamic simulation of Low Immersion End Milling Operation: Effect of cutting depth and feed rate

In end milling operation, cutting forces induce vibration on tool, workpiece and clamping devices which affects surface integrity and quality of the product. In this process, to select the optimum end mill and machine tool, the prediction of exact cutting forces is of prime importance. In the present work, modeling and simulation of cutting forces in end milling operation are performed. Instantaneous chip geometry is predicted using a 3D simulation software, the effect of cutting depth and feed rate are calculated and cutting conditions are predicted before any machining operation.