Study of cutting force in ultra-precision raster milling of V-groove

Cutting force plays an important role in the design of cutting plans, setting of cutting conditions, inspection of tool wear, and prediction of machined surface topography. As no previous research has focused on cutting force in ultra-precision raster milling (UPRM), this paper presents a theoretical and experimental study on cutting force modeling in UPRM of V-groove. An analytic cutting force model is established to predict the cutting force components both in the feed direction and thrust direction, and a dynamic model is developed to simulate the free vibration signal induced by the cutting force pulse. The effects of cutting parameters in UPRM are studied, including the depth of cut and feed rate, and a group of experiments conducted to verify the simulation results. The simulation and experimental results show that cutting force in UPRM is figured as a force pulse followed by a free vibration signal induced by the force pulse and that the amplitudes of cutting force in both feed direction and thrust direction increase with the growing depth of cut and feed rate.