High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

Abstract

High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

“…The advantage of this method is the possibility of mac arc fir tree slots [58][59][60][61][62]. Jianhua et al noticed that milling in a single machining pass may lead to sub the cutter to very high thermal loads and, as a result, accelerated tool wear (Figu Therefore, dividing the profile of the slot into a few parts and machining the subse sides and bottom of the slot was proposed [63][64][65][66]. Surface roughness after milli pending on the machining strategy is usually in the range of approximately Rz 2.1 5.9 μm [67][68][69].…”

Modelling of the Face-Milling Process by Toroidal Cutter

“…This kind of milling process is used mainly in the five-axis milling of sculptured surfaces and also in the milling of flat surfaces [ 1 , 2 , 3 ]. The face-milling process can be carried out with the use of different types of milling cutters with either a straight or curved cutting edge [ 4 ]. Face mills are characterised by the fact that the cutting edge has an entry angle below 90° and is located on the face part of the tool [ 5 ].…”

“…The entering angle is one of the basic geometric parameters of the cutting tool and has a great influence on the cutting process. It has an impact, among others, on the components of the cutting force, the stability of the process, or the topography of the surface [ 4 , 8 ]. The effect of the entering angle on the cutting process was tested by Amigo et al [ 9 ], but only in the turning process.…”

An Experimentally Aided Operational Virtual Prototyping to Obtain the Best Spindle Speed during Face Milling of Large-Size Structures

“…Hao et al noted [ 2 ] that they impose significant restrictions on the further increase in productivity and product quality. In order to increase machining efficiency, Płodzień et al proposed a new method called high feed milling [ 3 ]. However, its use results in a significant increase in the cutting force components and, as a consequence, the vibration level and deterioration of the surface roughness.…”