Chip thickness analysis for different tool motions for adaptive feed rate

Abstract In face milling, the trajectory of the cutter presents a linear and circular interpolation. There are some works published on the modelling of the undeformed chip thickness case of linear interpolation. However, very little work has been done in research of chip thickness in circular interpolation. When the cutter moves in the circular motion, the chip thickness increases, as well as the radius of circular trajectory decreases. This phenomenon which is important to model, causing a thermal and mechanical shock in the cutter and influence the surface roughness. In this study, the stable cutting process was considered. The method is described for calculating the instantaneous undeformed chip thickness in face milling, case of circular interpolation and it was compared with the case of linear interpolation. A numerical method used to determine the adaptive feed per tooth to maintain the maximum chip thickness under the programmed feed.