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Published on: January 20, 2023
Comprehensive Analysis of Cutting-Force Components in Milling Using RQA: Effect of Edge Geometry and Process
Marcin Płodzień1, Łukasz Żyłka1, Michał Wydra2
1Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, W. Pola Str. 2, 35-959 Rzeszow, Poland.
None:
This study investigates the influence of cutting edge geometry (continuous, serrated, and wavy) and selected machining parameters (cutting speed vc, feed per tooth fz, and radial infeed ae) on cutting-force components and dynamic behavior during the milling of an AlZn5.5MgCu aluminum alloy. The analysis was based on box plots and Recurrence Quantification Analysis (RQA) applied to the cutting-force signal. The results demonstrated that serrated and wavy-edge tools generated significantly lower values of the normal force component FfN-up to -57% on average-compared to the continuous-edge tool, particularly at lower fz and vc, indicating enhanced process dynamics. At higher ae values, however, these tools induced increased signal variability-up to 300% greater-suggesting potential resonance excitation. RQA indicators, such as DET, Lmax, and LAM, revealed a strong dependence of system dynamics on tool edge geometry. Linear Discriminant Analysis (LDA) confirmed that RQA measures effectively distinguish between cutting-edge types. The study concludes that tooldge geometry substantially affects milling process stability and can be purposefully selected to optimize performance under varying machining conditions.
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