Mathematical Prediction Model of Cutting Forces and Intuitive Representation Based on Experimental Study of High-Speed Milling of Ti6A14V

Abstract

Cutting forces in high speed machining of titanium alloy Ti6A14V are generally measured by experiments and the experimental cost is very high. In this work we dealt with the experimental data of cutting forces using the Second Order Response Surface (SORS) method, and then established SORS prediction model of cutting forces within the normally used ranges of the cutting parameters, i.e. milling speed 130mlmin $\leq v_{c}\leq 160$ m/min, feed rate 0.04mm/tooth $\leq f_{z}, \leq 0.07$ mm/tooth, and axial depth of cut O.lmm $\leq a_{p}\leq 0.4$ mm. The analysis of variance (ANOVA) and F-test prove the effectiveness of the model only with the average percentage error of 5.02 % • The advantage of the SORS method lies in that the established SORS prediction model can be used to provide a basis for predicting and evaluating the milling forces without doing more machining experiments in the investigated parameters range in practice. Also, the method of modeling can intuition ally reflect the change trends of the forces through the three dimensional (3D) SORS graphs. Thus it is a new thinking and more applicable way of predicting cutting forces.