Cutting Force in Dry Slot-Milling of Hastelloy X

Abstract

AbstractIncreasing spindle speed accompanied with decreasing feed per tooth during slot-milling of nickel-based superalloys, is a common approach in aircraft manufacturing industry for achieving low cutting force. This is due to nickel-based superalloys is difficult-to-machine materials, thus increase in spindle speed will lead to thermal softening that may reduce cutting force, while decrease in feed per tooth will decrease the amount to shear unwanted material at the tool edge and may avoid excessive cutting force. By considering this approach, an effective validation is vital. This manuscript elucidates the influence of spindle speed and feed per tooth during dry slot-milling of Hastelloy X on cutting force. Conventional-milling and climb-milling are performed experimentally using Kennametal KYS40 solid ceramic end-mill. Experimental results indicate that cutting force firstly decrease and then increase with increase in spindle speed, whereas cutting force increases with increase in feed per tooth. Feed per tooth has significant effect on cutting force. In contrast, spindle speed, and the interaction between spindle speed and feed per tooth have effect on cutting force but not significant. The lowest cutting force can be obtained using medium spindle speed (24,100 rev/min) accompanied with lowest feed per tooth (0.013 mm/tooth), instead of using highest spindle speed (26,800 rev/min) accompanied with lowest feed per tooth (0.013 mm/tooth).KeywordsDry slot-millingASME SB435 Hastelloy XCutting force