A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

Abstract

The high-speed milling technology for difficult-to-machine material has come to be a hotspot in the industry field. Regarding the high-speed milling of Inconel 718 parts with curved surface, the variation of the geometric features of the curved surface will lead to the sharp fluctuation of the cutting force as well as the vibration of machine tool. In this way, it not only makes a severe impact on the surface machining quality and the tool life but also greatly affects the efficiency of the high-speed milling. For the milling force is an important physical concept to comprehensively reflect the milling process and the cutting speed is one of the main factors that affect the cutting force when the cutting volume is small in the high-speed milling of Inconel 718 parts with curved surface, a new cutting force modeling method is proposed based on the geometric characteristics of the curved surface and the spindle speed, which can be used to predict the cutting force fluctuation under different cutting speed. The experimental results show that the proposed cutting force model can effectively forecast the amplitude and the change trend of the cutting force. The achievements of this study will provide the theoretical basis for the optimization of machining parameters in high-speed milling of curved surface with difficult-to-machine material and enrich the processing and manufacturing theory for parts with curved surface.