Effect of chip load and spindle speed on cutting force of Hastelloy X

Abstract

Research on cutting force revealed that the cutting force decreases as cutting speed increases, which is in line with Salomon’s Theory. However, the fundamental behaviour was never clearly explained because most studies had focused on increasing the cutting speed by increasing spindle speed without retaining the rate of chip load. On that note, the effect of increasing spindle speed while chip load is constant on the cutting force of Hastelloy X is presented in this paper. Third Wave AdvantEdge software was applied and half-immersion up-milling simulations were conducted in dry condition. Result showed that the resultant force was primarily affected by the axial force, followed by normal force and feed force. Trend-lines indicated that the behaviour of cutting force components and resultant force was quadratic. Desirability Function Analysis (DFA) results revealed that the optimum combination of chip load and spindle speed led to lowest cutting force components and resultant force was at 0.013 mm/tooth and 24,100 RPM. Furthermore, the optimum cutting conditions that led to the lowest cutting force components and resultant force at chip loads of 0.016 mm/tooth and 0.019 mm/tooth was 24,100 RPM also. Therefore, increasing Material Removal Rate (MRR) while minimizing cutting force components and resultant force can be achieved by increasing the amount of chip load at spindle speed of 24,100 RPM.

Correlation Between Cutting Force and Residual Stress in Dry End-Milling of Inconel HX

“…When the spindle speed is in the range of 21,400 to 24,100 rpm, the cutting force decreases, whereas it begins to increase when the spindle speed ranges from 24,100 to 26,800 rpm. This phenomenon might be associated with ductile-to-brittle transition and in agreement with the result of previous research by Mohd Nor et al (2020). This is also supported by Wang et al (2015), where they claimed that the machined material experiences plastic deformation at critical cutting speed during the transition from ductile regime to brittle regime, which subsequently leads to a decrease in cutting force then increases after reaching a minimum cutting force value.…”