Effect of Process Parameters to the Main Cutting Force in Milling

Abstract

There are many approaches to predict the average pressure acting in the cutting zone, and these are usually based on specific cutting force and the cutting resistance. Common theme for these modelling approaches is to use chip thickness to describe the uncut chip. These models are usually based on process parameters such as the depth of cut a_p, radial engagement a_e and feed per tooth f_z. The purpose of this paper is to investigate the underlying process parameters affecting the main cutting force in milling operations using the Full Factorial Design model. For this study, single-tooth climb milling with indexable carbide inserts in medium carbon steel C45E, were selected. The design, and experiment, and analysis were performed using Modde Pro. During the test, the main cutting force was measured with a dynamometer and compared with the results from the FFD model. These results revealed that the inclusion of the interaction of parameters in the model was important for the model accuracy. As expected, it also shows that any increase of a_e, a_p, and f_z will increase the main cutting force and therefore all three parameters should be included in a DoE, when modelling main cutting force in milling. In conclusion, a statistical approach can be used to calculate the main cutting force, complementing the traditional models that are based on cutting resistance and chip thickness.