In the present study, the impact of cutting-edge microgeometry on the cutting forces in the finish milling of a 7075-aluminium alloy was analysed. The influence of selected values of the rounding radius of cutting edge, and the size of the margin width, on the cutting-force parameters was analysed. Experimental tests were carried out for different cross-sectional values of the cutting layer, changing the feed per tooth and radial infeed parameters. An analysis of the various statistical parameters of the force signal was performed. Experimental mathematical models of the relationship of the force parameters to the radius of the rounded cutting edge and the width of the margin were developed. The cutting forces were found to be most strongly influenced by the width of the margin and, to a minor extent, by the rounding radius of the cutting edge. It was proved that the effect of margin width is linear, and the effect of radius R is nonlinear and nonmonotonic. The minimum cutting force was shown to be for the radius of rounded cutting edge of about 15–20 micrometres. The proposed model is the basis for further work on innovative cutter geometries for aluminium-finishing milling.
An analysis of the accuracy of generating a solid mode based on the created surfaces is presented. In the process of creating a digital model, reconstructive engineering methods were used. The accuracy of mapping of the created solid model was determined on the basis of surface models generated by changing the tolerance value of triangles.
The analytical and numerical model of the cross-section of the machined layer in the process of milling of concave rounding is presented. Simulation tests were carried out to determine the cross-sectional area of the cutting layer. A strategy has been developed that allows to increase the stability of the cross-section area of the cutting layer when the mill enters the inner corner area.
The simulation of the cutting layer in the CAD system during milling internal corners of elements with complex geometry has been presented. A case of variable cutting width in the finishing process was considered and the strategy of multitransitional corner milling was analyzed.
Presented is the method of analysis of a machined layer in a CAD system in milling process, and described is the methodology of this type of research. The influence on the area of contact between the tool and the workpiece caused by geometry of the workpiece and the angles of wrapping was determined.
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