Helical milling is one of the novel hole-making methods to create a hole with high accuracy and quality. In this study, the helical milling process is dynamically modeled using a set of second-order differential equations. In this modeling, the tool is considered a cantilever beam with a degree of freedom in all three directions of x, y, and z. Experimental tests were conducted to investigate the validity of the obtained theoretical relations and the effects of different parameters such as material, diameter, and rotational speed of the cutting tool on the precision of the created hole. The error of the theoretical relations in predicting the hole diameter is 2.7%, indicating the high precision of the accomplished modeling. Theoretical relations show that the error of the chip removal path decreases by increasing each of the parameters, namely, tool stiffness, the rotational speed of the tool, tool diameter, and tangential feed per tooth. In contrast, the error of the chip removal path increases by increasing each of the parameters, namely, the speed of the tool in the helical path and axial feed per tooth. It has been shown that improving the cutting tool material in terms of strength or increasing the rotational speed of the tool and the cutting tool diameter causes a reduction in the diametrical error. It has been shown that the diametrical error rate is 0.9% with the change of the cutting tool from HSS-E to carbide, and it has reduced to 0.6% by increasing the rotational speed of the tool from 900 r/min to 2100 r/min.

螺旋铣削是一种新颖的孔加工方法，可以加工出高精度和高质量的孔。在这项研究中，螺旋铣削过程使用一组二阶微分方程动态建模。在此建模中，该工具被视为在x、y和z三个方向均具有自由度的悬臂梁. 进行了实验测试，以研究所获得的理论关系的有效性以及刀具材料、直径和转速等不同参数对加工孔精度的影响。预测孔径的理论关系误差为2.7%，表明所完成的建模精度较高。理论关系表明，通过增加每个参数，即刀具刚度、刀具转速、刀具直径和每齿切向进给量，排屑路径的误差减小。相比之下，排屑路径的误差随着每个参数的增加而增加，即螺旋路径中的刀具速度和每齿轴向进给量。已经表明，在强度方面改进刀具材料或增加刀具转速和刀具直径会导致直径误差减小。研究表明，刀具由HSS-E改为硬质合金时，直径误差率为0.9%，刀具转速从900 r/min提高到2100 r/min时，直径误差率降低到0.6%。分钟