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Modelling of the Face-Milling Process by Toroidal Cutter.

Marcin Płodzień1, Łukasz Żyłka1, Antun Stoić2

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Summary
This summary is machine-generated.

Face milling with toroidal cutters shows depth of cut significantly impacts cutting forces and surface roughness. Feed per tooth has minimal effect, with roughness peaking around 2mm depth.

Keywords:
cutting forceforce modelroughness modelsurface roughnesstoroidal cutter

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Toroidal cutters are increasingly used in face milling operations.
  • Understanding the influence of cutting parameters on forces and surface quality is crucial for process optimization.

Purpose of the Study:

  • To experimentally investigate the effect of cutting depth and feed per tooth on cutting forces and surface roughness in face milling with toroidal cutters.
  • To compare experimental results with Finite Element Method (FEM) analysis.

Main Methods:

  • Experimental testing using a DMU 100 monoBLOCK CNC machine.
  • Measurement of cutting force components and surface roughness parameters (Ra, Rz, RSm).
  • Finite Element Method (FEM) analysis of the face milling process.

Main Results:

  • Depth of cut was identified as the most influential parameter on cutting forces.
  • Feed per tooth had a minor impact on cutting forces.
  • FEM analysis showed an average deviation not exceeding 12% compared to experimental results.
  • Surface roughness exhibited a nonlinear and nonmonotonic relationship with depth of cut, with a maximum around 2mm.

Conclusions:

  • Depth of cut is the primary factor affecting cutting forces and surface roughness in toroidal face milling.
  • FEM analysis provides a reliable approximation of the experimental outcomes.
  • Optimizing depth of cut is key to controlling surface quality and machining efficiency.