The Effect of Cutting Speed and Feed on Cutting Forces in Face Milling with Square Shaped Insert

Abstract

Metal cutting operations are usually employed for the manufacturing of various components in the automotive and aerospace industries. Especially, face milling is particularly preferred for creating high quality surfaces for high-end components, due to its versatility and high efficiency. A major challenge of this process is the achievement of essential goals, such as low surface roughness, minimum deformation and workpiece damage, avoidance of unfavorable residual stresses and at the same time the achievement of high productivity, i.e. high material removal rate. For that reason, it is essential to determine the optimum process parameters in order to reach the necessary compromise between productivity and quality of the manufactured product. In the present study, the effect of feed and cutting speed on cutting forces and specific cutting forces during face milling with square shaped cutting insert is investigated and conclusions are drawn on the importance of each process parameter, as well as the recommended values of these parameters in order to achieve the desired goals.