Prediction of cutting force based on machining parameters on AL7075‐T6 aluminum alloy by response surface methodology in end milling

Abstract

Cutting forces modeling is the basic to understand the cutting process, which should be kept in minimum to reduce tool deflection, vibration, tool wear and optimize the process parameters in order to obtain a high quality product within minimum machining time. In this paper a statistical model has been developed to predict cutting force in terms of geometrical parameters such as rake angle, nose radius of cutting tool and machining parameters such as cutting speed, cutting feed and axial depth of cut. Response surface methodology experimental design was employed for conducting experiments. The work piece material is Aluminum (Al 7075‐T6) and the tool used is high speed steel end mill cutter with different tool geometry. The cutting forces are measured using three axis milling tool dynamometer. The second order mathematical model in terms of machining parameters is developed for predicting cutting forces. The adequacy of the model is checked by employing ANOVA. The direct effect of the process parameter with cutting forces are analyzed, which helps to select process parameter in order to keep cutting forces minimum, which ensures the stability of end milling process. The study observed that feed rate has the highest statistical and physical influence on cutting force.

Performance evaluation of different carbide inserts in turning of newly developed Al‐12Si‐0.1Sr alloy

“…In other words, due to the increase in feed rate, the temperature that causes the softening of the cutting tool material arises. This temperature increases the cutting force and causes poor surface quality [45,48]. The built-up edge and built-up layer result from the transfer of workpiece material to the cutting insert surface by means of chips [49].…”

“…As the cutting speed increases, the heat generation in the primary cutting zone increases; thus, the yield strength of the chip decreases, and the cutting process becomes easier [44]. In addition, less built‐up edge and built‐up layer occur, and better surface quality can be achieved [17, 45]. The built‐up edge and built‐up layer increased with increasing feed rate.…”

A mechanistic approach to predict cutting forces based on cutting force coefficients in slot milling Al-7075

“…6) in tool coordinate system are transformed to universal (X, Y, and Z) axes employing the transformation matrix to get Eq. (7). Equation ( 7) is a mechanistic milling force model comprising differential forces for 'j th ' tooth at very small instantaneous depth of cut (z) based on discretization approach.…”

“…The empirical models rely on extensive experimentation for determining the cutting force as a function of significant parameters like feedrate, cutting speed, and axial/radial depths. The forces are expressed in terms of machining parameters, number of exponents and coefficients using various statistical tools [5][6][7]. The empirical models do not reflect the variation in forces with tool movement as they neglect interface friction, shear, and other complexities in metal cutting.…”

Investigation of the Combined Effects of Ultrasonic Vibration-Assisted Machining and Minimum Quantity Lubrication on Al7075-T6

“…Nonetheless, its comparatively poor machinability, when contrasted with other commercially available aluminum alloys, presents challenges during various manufacturing processes [2]. Inadequate machining conditions can lead to reduced cutting efciency, increased cutting forces [3], rapid tool wear [4], high tool consumption, and inadequate surface fnish [5], necessitating secondary operations. Moreover, the excessive use of cutting fuids is demanded in order to achieve a successful cutting which is detrimental for the environment [2,6].…”