Cutting Force Modeling Considering Wiper Edge Cutting Effect During Face Milling of 316H Stainless Steel and Experimental Verification

Abstract Wiper tools are revered for their capacity to simultaneously achieve high-quality and high-efficient machining. Nonetheless, the cutting mechanism of wiper tools remains unclear, and the cutting force prediction model of wiper tools has not been reported, leading to severe wear of the bottom wiper edge and unstable cutting in machining processes. In this study, the cutting mechanism of wiper tools is systematically analyzed, and the mechanistic cutting force model considering the wiper edge cutting effect was established. The cutting force coefficients were calibrated by the cutting force separation method, which can quickly calibrate the cutting force coefficients for the flank cutting region dominated by the shear effect, the bottom cutting region dominated by the shear effect, and the bottom wiper region dominated by plough effect. Compared with measured cutting forces, the maximum average absolute errors in the predicted forces are 9.2 %, 7.6 %, and 9.3 % in the x, y, and z directions, respectively. Furthermore, the feed rate and the length of the wiper edge were primary determinants of the bottom-edge cutting forces. This study provides theoretical guidance and technical support for the wear mechanism and design of wiper tools.