Assessment of cutting force coefficient identification methods and force models for variable pitch and helix bull-nose tools

The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average $F_x$, $F_y$ and $F_z$ cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.