Manufacturing Technology 2018, 18(3):431-438 | DOI: 10.21062/ujep/117.2018/a/1213-2489/MT/18/3/431

Analysis of the Effect of Feed on Chip Size Ratio and Cutting Forces in Face Milling for Various Cutting Speeds

János Kundrák1, Angelos P. Markopoulos2, Tamás Makkai1, István Deszpoth1, Antal Nagy1
1 Institute of Manufacturing Science, University of Miskolc, Egyetemváros H-3515 Miskolc, Hungary
2 Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, Heroon Polytechniou 9, 15780 Athens, Greece

Face milling is one of the most common machining processes used for the production of high quality flat surfaces. Another important feature of the process is the high material removal rate that can be achieved, or in the case of milling performed at one pass, the high surface rate. Surface rate is increased by increasing feed and cutting speed; both are bound by technological limitations and are limited to rather small variations, especially cutting speed. In finishing face milling, if feed per tooth is increased, subsequently the shape of the chip cross section is altered. This results in the change of the loads of the cutting edges, which influences the cutting forces and process efficiency. In this study, an experimental investigation is carried out in order to determine the influence of feed on chip size ratio. For this purpose, five different values of feed, at two different cutting speeds are tested for face milling. It is concluded that an increase in feed from 0.1 to 1.6 mm results in eight-fold increase of cutting force Fc while surface rate proportionally increases 16 times and specific cutting force only 0.5 times.

Keywords: face milling, cutting forces, feed rate, chip size ratio, force measurement, high speed machining, material removal rate, surface rate

Published: June 1, 2018  Show citation

ACS AIP APA ASA Harvard Chicago IEEE ISO690 MLA NLM Turabian Vancouver
Kundrák J, Markopoulos AP, Makkai T, Deszpoth I, Nagy A. Analysis of the Effect of Feed on Chip Size Ratio and Cutting Forces in Face Milling for Various Cutting Speeds. Manufacturing Technology. 2018;18(3):431-438. doi: 10.21062/ujep/117.2018/a/1213-2489/MT/18/3/431.
Share...
Download citation
  • BibTeX (.bib)
  • Bookends (.ris)
  • EasyBib (.ris)
  • EndNote (.enw)
  • EndNote 8 (.xml)
  • ISI WoS (.isi)
  • Medlars (.medlars)
  • Mendeley (.ris)
  • MODS (.xml)
  • Papers (.ris)
  • RefWorks (.txt)
  • RefManager (.ris)
  • RIS (.ris)
  • MS Word (.xml)
  • Zotero (.ris)
    • Open full article

    References

    1. ILLÉS, B., TAMÁS, P., DOBOS, P, SKAPINYECZ, R. (2017) New challenges for quality assurance of manufacturing processes in industry 4.0. Solid State Phenomena. 261, 481-486, DOI 10.4028/www.scientific.net/SSP.261.481. Go to original source...
    2. MUÑOZ-ESCALONA, P., MAROPOULOS, P.G. (2015) A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools. Journal of Manufacturing Systems. 36, 216-223, DOI 10.1016/j.jmsy.2014.06.011. Go to original source...
    3. HABRAT, W., MOTYKA, M., TOPOLSKI, K., SIENIAWSKI, J. (2016) Evaluation of the cutting force components and the surface roughness in the milling process of micro-and nanocrystalline titanium. Archives of Metallurgy and Materials. 61(3), 1033-1038, DOI 10.1515/amm-2016-0226. Go to original source...
    4. KORKUT, I., DONERTAS, M.A. (2007) The influence of feed rate and cutting speed on the cutting forces, surface roughness and tool-chip contact length during face milling. Materials & Design. 28, 308-312, DOI 10.1016/j.matdes.2005.06.002. Go to original source...
    5. SILLER H., VILA, C., RODRÍGUEZ, C., ABELLÁN, J. (2009) Study of face milling of hardened AISI D3 steel with a special design of carbide tools. International Journal of Advanced Manufacturing Technology. 40, 12-25, DOI 10.1007/s00170-007-1309-0. Go to original source...
    6. ZHENG, H.Q., LI, X.P., WONG, Y.S., NEE, A.Y.C. (1999) Theoretical modelling and simulation of cutting forces in face milling with cutter runout. International Journal of Machine Tools and Manufacture. 39, 2003-2018, DOI 10.1016/S0890-6955(99)00023-1. Go to original source...
    7. LI, X.P., ZHENG, H.Q., WONG, Y.S., NEE, A.Y.C. (2000) An approach to theoretical modeling and simulation of face milling forces. Journal of Manufacturing Processes. 2(4), 225-240, DOI 10.1016/S1526-6125(00)70024-7. Go to original source...
    8. KUNDRÁK, J., GYÁNI, K., FELHŐ, C., DESZPOTH, I. (2017) The Effect of the Shape of Chip Cross Section on Cutting Force and Roughness when Increasing Feed in Face Milling. Manufacturing Technology. 17(3), 335-342. Go to original source...
    9. KUNDRÁK, J., DESZPOTH, I., MOLNÁR, V. (2014) Comparative study of material removal in hard machining of bore holes. Tehnicki Vjesnik. 21(1), 183-189.
    10. PIMENOV, D. YU., GUZEEV, V. I., MIKOLAJCZYK, T., PATRA, K. (2017) A study of the influence of processing parameters and tool wear on elastic displacements of the technological system under face milling. International Journal of Advanced Manufacturing Technology. 92, 4473-4486, DOI 10.1007/s00170-017-0516-6. Go to original source...
    11. MATRAS, A., ZȨBALA, W., KOWALCZYK, R. (2014) Precision milling of hardened steel with CBN tools. Key Engineering Materials. 581, 182-187, DOI 10.4028/www.scientific.net/KEM.581.182.
    12. PIMENOV, D.Y. (2015) Mathematical modeling of power spent in face milling taking into consideration tool wear. Journal of Friction and Wear. 26(1), 45-48, DOI 10.3103/S1068366615010110. Go to original source...
    13. I®OL, P., VRABEĄ, M., MAŇKOVÁ, I. (2016) Comparison of milling strategies when machining freeform surfaces. Materials Science Forum. 862, 18-25, DOI 10.4028/www.scientific.net/MSF.862.18. Go to original source...
    14. DUDAS, I., VARGA, G. (2005) 3D topography for environmentally friendly machined surfaces. Journal of Physics: Conference Series. 13 (1), 24-27, DOI 10.1088/1742-6596/13/1/006 Go to original source...
    15. SAÏ, K., BOUZID, W. (2005) Roughness modeling in up-face milling. International Journal of Advanced Manufacturing Technology. 26, 324-329, DOI 10.1007/s00170-004-2305-2. Go to original source...
    16. FRANCO, P., ESTREMS, M., FAURA, F. (2008) A study of back cutting surface finish from tool errors and machine tool deviations during face milling. International Journal of Machine Tools and Manufacture. 48, 112-123, DOI 10.1016/j.ijmachtools.2007.07.001. Go to original source...
    17. HADAD, M., RAMEZANI, M. (2016) Modeling and analysis of a novel approach in machining and structuring of flat surfaces using face milling process. International Journal of Machine Tools and Manufacture. 105, 32-44, DOI 10.1016/j.ijmachtools.2016.03.005. Go to original source...
    18. SURESH KUMAR REDDY, N., VENKATESWARA RAO, P. (2005) Selection of optimum tool geometry and cutting conditions using a surface roughness prediction model for end milling. International Journal of Advanced Manufacturing Technology. 26(11-12), 1202-1210, DOI 10.1007/s00170-004-2110-y. Go to original source...
    19. AYKUT, Ş., GÖLCÜ, M., SEMIZ, S., ERGÜR, H.S. (2007) Modeling of cutting forces as function of cutting parameters for face milling of stellite 6 using an artificial neural network. Journal of Materials Processing Technology. 190(1-3), 199-203, DOI 10.1016/j.jmatprotec.2007.02.045. Go to original source...
    20. JESUTHANAM, C.P., KUMANAN, S., ASOKAN, P. (2007) Surface roughness prediction using hybrid neural networks. Machining Science and Technology. 11(2), 271-286, DOI 10.1080/10910340701340141. Go to original source...
    21. BHARATHI RAJA, S., BASKAR, N. (2012) Application of particle swarm optimization technique for achieving desired milled surface roughness in minimum machining time. Expert Systems with Applications. 39(5), 5982-5989, DOI 10.1016/j.eswa.2011.11.110. Go to original source...
    22. ARRAZOLA, P.J., ÖZEL, T., UMBRELLO, D., DAVIES, M., JAWAHIR, I.S. (2013) Recent advances in modelling of metal machining processes. CIRP Annals-Manufacturing Technology. 62(2), 695-718, DOI 10.1016/j.cirp.2013.05.006. Go to original source...
    23. KASELOURIS, E., PAPADOULIS, T., VARIANTZA, E., BAROUTSOS, A., DIMITRIOU, V. (2017) A study of explicit numerical simulations in orthogonal metal cutting. Solid State Phenomena. 261, 339-346, DOI 10.4028/www.scientific.net/SSP.261.339. Go to original source...
    24. NIESLONY, P., GRZESIK, W., BARTOSZUK, M., HABRAT, W. (2016) Analysis of mechanical characteristics of face milling process of Ti6Al4V alloy using experimental and simulation data. Journal of Machine Engineering. 16(3), 58-66.
    25. ZHANG, Q., ZHANG, S., LI, J. (2017) Three Dimensional Finite Element Simulation of Cutting Forces and Cutting Temperature in Hard Milling of AISI H13 Steel. Procedia Manufacturing. 10, 37-47, DOI 10.1016/j.promfg.2017.07.018. Go to original source...
    26. GYLIENĖ, V., EIDUKYNAS, V. (2016)The numerical analysis of cutting forces in High Feed face milling, assuming the milling tool geometry. Procedia CIRP. 46, 436-439, DOI 10.1016/j.procir.2016.03.132. Go to original source...
    27. KUNDRÁK, J., MAKKAI, T., DESZPOTH, I. (2017) Effect of cutting feed and chip size ratio on cutting force. Solid State Phenomena. 261, 3-8, DOI 10.4028/www.scientific.net/SSP.261.3. Go to original source...
    28. KUNDRÁK, J., FELHŐ, C. (2016) 3D roughness parameters of surfaces face milled by special tools. Manufacturing Technology. 16(3), 532-538. Go to original source...
    29. KARPUSCHEWSKI, B, BATT, S. (2007) Improvement of Dynamic Properties in Milling by Integrated Stepped Cutting. CIRP Annals-Manufacturing Technology. 56(1), 85-88, DOI 10.1016/j.cirp.2007.05.001. Go to original source...
    30. KARPUSCHEWSKI, B., KUNDRÁK, J., EMMER, T., BORYSENKO, D. (2017) A new strategy in face milling - inverse cutting technology. Solid State Phenomena. 261, 331-338, DOI 10.4028/www.scientific.net/SSP.261.331. Go to original source...

    This is an open access article distributed under the terms of the Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0), which permits non-comercial use, distribution, and reproduction in any medium, provided the original publication is properly cited. No use, distribution or reproduction is permitted which does not comply with these terms.


    Return to the content