“This research presents the results of the development of a mechanistic cutting force prediction model for the wavy-edge bull-nose helical endmill (WEBNHE). The mechanistic model was developed to predict cutting force components and the resultant cutting force in high-speed end-milling of Inconel 718 under two cooling strategies: emulsion and Minimum Quantity Lubrication (MQL). The effects of the cooling strategies are incorporated into the mechanistic model through six cutting force coefficients (Ktc, Krc, Kac), and edge force coefficients (Kte, Kre, Kae), which have been experimentally identified in a separate research. The mechanistic model was validated by conducting end-milling experiments on Inconel 718 using a WEBNHE of 1.25” diameter under emulsion and MQL cooling strategies. In addition to cutting forces prediction, the mechanistic cutting force prediction model is used to investigate the effects of the cooling strategy, and the effects of the geometric parameters of the WEBNHE on the predicted cutting force components and the resultant cutting force. The geometric parameters investigated in this research were: wave magnitude, wave length, axial shift, and the helix angle. The cutting force components and the resultant cutting force predicted by this mechanistic cutting force model under the two cooling strategies were in good agreement with the experimental results. Additionally, the results show that an increase in the depth of cut under MQL generates less cutting force than the same increase under emulsion. Moreover, all predicted cutting force components increase when the magnitude of the WEBNHE increases, whereas they decrease when the wave length, axial shift, and the helix angle increase”--Abstract, page iv
