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Modelling of the Face-Milling Process by Toroidal Cutter
Marcin Płodzień1, Łukasz Żyłka1, Antun Stoić2
1Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland.
Materials (Basel, Switzerland)
|April 13, 2023
Summary
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.
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.
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