Comparative study and experimental validation of cutting forces in high-speed ball-end milling for AL 7075-T6 and AL 6061-T6 alloys

Abstract

This study examines the importance of precise cutting force prediction during high-speed ball-end milling of the AL 7075-T6 and AL 6061-T6 aluminum alloys, which are widely used in the aerospace and automotive industries, because to their strength and fatigue resistance. Predicting cutting forces is critical for optimizing milling conditions and creating high-quality surfaces. We have used a mechanistic model to estimate cutting forces based on experimental data. To generate the more precise predictions, the developed model takes into account tool geometry, cutting settings and material properties. We have measure the cutting forces on a CNC SOMAB DIAM 850 milling machine by using a Kistler 9257A dynamometer. We have done simulations with MATLAB software. The results reveal that the mechanistic model accurately predicts both alloys. ALU 7075-T6 produces higher cutting forces because to its increased strength. This comparative research demonstrates that the mechanistic approach is useful in forecasting cutting forces in high-speed ball-end milling of aluminum alloys, providing useful insights for improving machining operations.