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In this work, a new mathematical model for determining the mechanism of plunging the cutting edge of end mills with a stable passage of the cutting into the workpiece material has been developed. The new mathematical model describes the chip width as a function of the feed rate, the number of teeth and the cutter diameter. The present work shows that the theoretical value of the width of the cut layer can be used as a key parameter controlling the cutting force and as a key factor determining the plunging mechanism. A comparison of model results with experimental data has shown that modeled and experimental heights of microroughness in the stable cutting sections are in agreement within 0.05 μm that indicates the high accuracy of the developed mathematical model.
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Petr M. Pivkin, Vladimir A. Grechishnikov, Ilya V. Minin, Mikhail Mosyanov, Alexsey B. Nadykto, "New method for detecting active infeed of cutting edge of end mills," Proc. SPIE 11868, Emerging Imaging and Sensing Technologies for Security and Defence VI, 1186813 (12 September 2021); https://doi.org/10.1117/12.2602036