Experimental investigations and development of cutting force model for self-propelled rotary face milling cutter in machining of titanium alloy

Abstract

In self-propelled rotary tool machining, a circular cutting tool insert is used that continuously rotates about its axis during machining, as the tool is fed into the workpiece. The continuous rotation of the insert allows the insert to cool between engagements and improves tool life. In order to make use of this methodology for rough machining and bulk material removal in machining of aerospace materials, a self-propelled rotary face milling cutter is developed at Defence Research and Development Laboratory, Hyderabad. This cutter was developed to study the influence of inclination angle on the cutting forces generated during machining, and hence the cutter is provided with the provision to have the inclination angle of the insert for 20°, 30°, 40° and 50°. This article discusses the performance of the developed self-propelled rotary face milling cutter in face milling of titanium alloy at different inclination angles. The cutting forces developed in FX, FY and FZ directions are evaluated at different cutting speed, feed, depth of cut and inclination angles. The cutting forces obtained in self-propelled rotary face milling cutter is compared with that of conventional face milling cutter and the results are presented and discussed. Finally, regression models for prediction of cutting forces are developed.