This review examines recent advancements and ongoing challenges in plunge milling. It is an increasingly utilised machining process renowned for its high material removal rates, particularly with hard-to-machine materials like hardened steels and titanium alloys. Plunge milling’s unique perpendicular tool path offers enhanced stability and reduced lateral cutting forces, making it valuable for applications that demand precision and efficiency, such as aerospace and automotive manufacturing. The paper systematically analyses and synthesises research on critical areas of plunge milling optimization, including tool geometry, material selection, coating technologies, and process parameters, highlighting strategies to mitigate common issues like rapid tool wear and chip evacuation difficulties. In this comprehensive overview, the review introduces theoretical and experimental findings on optimizing plunge milling tools and process parameters—such as cutting speed, feed rate, and coolant delivery—that are essential for improving performance and achieving desirable surface finishes. The paper also explores innovative trends, including AI-driven optimization algorithms and hybrid machining systems, which hold promise for addressing persistent limitations and enhancing plunge milling’s industrial applicability. By consolidating findings from recent studies, this review contributes to a deeper understanding of plunge milling’s role in high-precision manufacturing and identifies future research directions for advancing the process. The insights presented offer practical and strategic implications, aiming to guide ongoing developments in plunge milling technology and its adoption across various precision-oriented industries.
Read full abstract