Side Oscillation Milling: Modeling, Analysis, and Compensation of Cutting Forces Through Feed Optimization

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Cutting forces in machining hardened steel are critical for process efficiency and tool life.
• Traditional milling methods can lead to high fluctuations in cutting forces, impacting surface finish and productivity.
• Oscillation machining offers a potential solution to mitigate these challenges.

Purpose of the Study:

• To analyze and model cutting forces during oscillation milling of hardened steel side surfaces.
• To investigate the impact of oscillation machining parameters, including feed rate and tool trajectory angles, on cutting forces.
• To evaluate the efficiency gains achieved through optimized oscillation milling.

Main Methods:

• Utilized a sinusoidal function to define the tool's oscillatory trajectory.
• Conducted 34 cutting tests with four end-mill cutters, varying feed rates and sinusoidal angles.
• Developed empirical mathematical models for cutting forces using the response surface method.

Main Results:

• The sinusoidal tool trajectory, combined with optimized feed rates, significantly reduced cutting force fluctuations.
• Achieved stabilization of cutting forces during the oscillation milling process.
• Demonstrated an approximate 30% increase in machining efficiency compared to conventional methods.

Conclusions:

• Oscillation milling with a sinusoidal tool path is an effective strategy for machining hardened steel.
• Optimizing feed rate in conjunction with tool trajectory enhances process stability and efficiency.
• This approach offers a novel method for sine wave period selection in machining.