An Investigation of the Process Parameters Choice Criterion for Cutting Force Coefficient Identifications in Slot Milling

Abstract

The influence mechanism of process parameter selection on the identification result of cutting force coefficient is not clear. There is no accepted choice criterion for how to choose appropriate process parameters in the slot milling. In this study, a milling force test system was set up, and the spindle speed, tool diameters, milling depth, number of tool teeth, and machining characteristics of the workpiece were taken as test factors in the slot milling. It is revealed that the identifications of the cutting force coefficient decrease with the increase of the tool speed, but are correlated with the tool diameter positively. While the dynamic cutting force increases with intensified milling depth, a larger milling depth may lead to an expansion of the contact area between the tool and the workpiece. Also, more workpiece material is removed simultaneously, and the milling depth and the number of tool teeth have almost no effect on the identifications. In addition, it is also found that materials with better milling performance, such as aluminum alloy, exhibit larger identification errors, which may be related to the “sticky knife” phenomenon during the process, compared with difficult-to-machine materials. The findings can provide a good reference for cutting force coefficient identification test.

Keywords

• Cutting force coefficient
• milling force calculation
• process parameter
• slot milling