Analysis of Tool Load Concerning the Cross-Sectional Size of Removed Material

Abstract

High-feed milling (HFM) represents a progressive manufacturing technology that has recently found widespread application across various industries. HFM is characterized by high machining speed, reduced cycle times, increased overall productivity, and increased tool life. Due to its versatility, HFM is a suitable technology for the application of various materials. The study deals with experimental analysis of cutting forces, machined surface integrity, and statistical evaluation in high-feed machining. In the present study, nickel-copper-based alloy (Monel) was chosen as the machined material, employing HFM with a monolithic ceramic milling cutter. The Monel material is characterized by its excellent mechanical properties and chemical resistance in harsh environments. During machining, cutting forces were recorded in three mutually perpendicular directions. This paper delves into the analysis of the impact of the depth of cut (ap), width of cut (ae), and lead-in angle (ε). The chosen evaluation characteristics encompass the tool load, primary profile, and the attained roughness of the machined surface. It is noteworthy that the technology under consideration predominantly aligns with the roughing phase of the manufacturing process. Additionally, the investigation incorporates a statistical analysis of the response surface pertaining to the cutting force components, namely Fx, Fy, Fz, and the resultant cutting force F.