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In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth ap) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on Sa (surface arithmetic mean deviation) and Sq (surface root mean square deviation) from high to low level is the v, the f, and the ap. When v = 600 m/min, ap = 0.5 mm, f = 0.1 mm/r, Sa and Sq are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, Fx reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases Fx. The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool’s life. The optimal milling processing parameters in this paper are the v = 600 m/min, ap = 0.5 mm, and f = 0.1 mm/r.

A magnetic field induced by an electromagnetic coil is the key variable that determines the performance of a magnetically driven actuator. The applicability of the empirical models of the coil turns, static resistance, and inductance were discussed. Then, the model of the mean magnetic field induced by the coil was established analytically. Based on the proposed model, the sinusoidal response and square-wave response were calculated with the wire diameter as the decision variable. The amplitude and phase lag of the sinusoidal response, the time-domain response, steady-state value, and the response time of the square-wave response were discussed under different wire diameters. From the experimental and computational results, the model was verified as the relative errors were acceptably low in computing various responses and characteristic variables. Additionally, the optimization on the wire diameter was carried out for the optimal amplitude and response time. The proposed model will be helpful for the analytical analysis of the mean magnetic field, and the optimization result of the wire diameter under limited space can be employed to improve the performance of a magnetically driven actuator.

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