Determination of a coupling equation for milling parameters based on optimal cutting temperature

Abstract

The optimization of cutting parameters has a great concern in the field of manufacturing process, especially the relationships among cutting parameters, with the study aiming at exploring a coupling equation to cutting parameters based on the optimal cutting temperature in the milling process of precipitation-hardening stainless steel with cemented carbide inserts. Initially, the association among the ratios of cutting tool wear of the machined surface, the cutting speed, and temperature was respectively investigated, with the ratio also used as an evaluating level of tool wear. Afterwards, the effects of the work hardening layer depth and the work hardening degree on the cutting speed and temperature were discussed in order to evaluate the machined surface quality. The results indicate that while the minimum tool wear occurred, the tool tip temperature at the cutting zone stayed the same with the minimum degree of work hardening appearing, which was defined as the optimal cutting temperature. An empirical formula for the cutting temperature and cutting parameters is explored using regression orthogonal experiment design, and then combined with optimum temperature. As a result, a coupling equation to cutting parameters is determined. Meanwhile, the mechanism of the minimal cutter wear is analyzed in accordance with the characteristics of cutting tool wear under several different machining conditions. The coupling equation could be put into an optimization model as a constraint. The results of this research would be beneficial to application of cooling liquids and cooling method to achieve cleaner production as well as the construction of a cutting database of metal materials.