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.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Kundrák, J., Markopoulos, A.P., Makkai, T., Deszpoth, I., Nagy, A.: Analysis of the effect of feed on chip size ratio and cutting forces in face milling for various cutting speeds. Manuf. Technol. 18(3), 431–438 (2018)
Karpuschewsk, B., Kundrák, J., Felhő, C., Varga, G., Sztankovics, I., Makkai, T., Borysenko, D.: Preliminary investigations for the effect of cutting tool edge geometry in high-feed face milling. In: Jármai, K., Bolló, B. (eds.) Vehicle and Automotive Engineering 2, VAE 2018. Lecture Notes in Mechanical Engineering, pp. 241–254. Springer, Cham (2018)
Borysenko, D., Karpuschewski, B., Wenzel, F., Kundrák, J., Felhő, C.: Influence of cutting ratio and tool macro geometry on process characteristics and workpiece conditions in face milling. CIRP J. Manufact. Sci. Technol. 24, 1–5 (2019)
Karpuschewski, B., Batt, S.: Improvement of dynamic properties in milling by integrated stepped cutting. Ann. CIRP 56(1), 85–88 (2007)
Selaimia, A.A., Yallese, M.A., Bensouillah, H., Meddour, I., Khattabi, R., Mabrouki, T.: Modeling and optimization in dry face milling of X2CrNi18-9 austenitic stainless steel using RMS and desirability approach. Measurement 107, 53–67 (2017)
Muñoz-Escalona, P., Maropoulos, P.G.: A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools. J. Manuf. Syst. 36, 216–223 (2015)
Nath, C., Brooks, Z., Kurfess, T.R.: Machinability study and process optimization in face milling of some super alloys with indexable copy face mill inserts. J. Manuf. Process. 20, 88–97 (2015)
Kundrák, J., Felhő, C.: 3D roughness parameters of surfaces face milled by special tools. Manuf. Technol. 16(3), 532–538 (2016)
San Milan Torrecillas, R., Seleznev, A.E., Gurin, V.D., Peretyagin, P.Y.: Specifics of Wear of Ceramic Cutting tool inserts featuring Al2O3-TiC dies when face milling hardened cast iron. Mater. Sci. Forum 876, 43–49 (2016)
Zhenyu, S., Luning, L., Zhanqiang, L.: Influence of dynamic effects on surface roughness for face milling process. Int. J. Adv. Manuf. Technol. 80, 1823–1831 (2015)
Gurdal, O., Wright, A., Carpenter, C., Blackmore, M.: Investigation of the performance of different face milling inserts to improve rough milling of SA508 Grade 3 forgings. In: Proceedings of the ASME 2018 Pressure Vessels and Piping Conference, PVP 2018, Prague, pp. 1–9 (2018)
Wertheim, R., Satran, A., Ber, A.: Modifications of the cutting edge geometry and chip formation in milling. Ann. CIRP 43(1), 63–68 (1994)
Li, X.P., Zheng, H.Q., Wong, Y.S., Nee, A.Y.C.: An approach to theoretical modeling and simulation of face milling forces. J. Manuf. Process. 2(4), 225–240 (2000)
Rodrigues, A.R., Coelho, R.T.: Influence of the tool edge geometry on specific cutting at high speed cutting. J. Braz. Soc. Mech. Sci. Eng. 29(3), 279–283 (2007)
Subramanian, M., Sakthivel, M., Sooryaprakash, K., Sudhakaran, R.: Optimization of cutting parameters for cutting force in shoulder milling of Al7075-T6 using response surface methodology and genetic algorithm. Procedia Eng. 64, 690–700 (2013)
Mourão, A., Slătineanu, L., Gonçalves-Coelho, A.M.: The effect of wiper edge inserts on the specific cutting energy in face milling of aluminium alloys. Int. J. Mod. Manuf. Technol. 2(2), 71–76 (2010)
Acknowledgement
The authors greatly appreciate the support of the National Research, Development and Innovation Office – NKFIH (No. of Agreement: OTKA K 116876).
This study was carried out as part of the EFOP-3.6.1-16-00011 “Younger and Renewing University – Innovative Knowledge City – institutional development of the University of Miskolc aiming at intelligent specialization” project implemented in the framework of the Szechenyi 2020 program. The realization of this project is supported by the European Union, cofinanced by the European Social Fund.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this paper
Cite this paper
Kundrák, J., Markopoulos, A.P., Karkalos, N.E., Makkai, T. (2020). The Effect of Cutting Speed and Feed on Cutting Forces in Face Milling with Square Shaped Insert. In: Durakbasa, N., Gençyılmaz, M. (eds) Proceedings of the International Symposium for Production Research 2019. ISPR ISPR 2019 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-31343-2_17
Download citation
DOI: https://doi.org/10.1007/978-3-030-31343-2_17
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-31342-5
Online ISBN: 978-3-030-31343-2
eBook Packages: EngineeringEngineering (R0)