Analysis of static forces in end milling of Toolox® 44

Abstract

With the development of the industrial sector, the constant necessity to improve manufacturing processes and reduce production time while delivering higher quality products calls for engineers and researchers to develop new materials and alloys. This new material with improved conditions requires testing, analysis and validation of their properties and characteristics, as well as their performance and machinability. The purpose of this paper is to analyze and evaluate the active and passive static forces in dry and flood lubrication-assisted end milling of Toolox® 44 with different cutting conditions. An experiment using 3-factor Box Behnken design with three controllable cutting parameters (cutting speed, axial depth of cut, feed per tooth) was used to evaluate their influence on the measured forces. The analysis of variance showed that ap was the most significant parameter. Multivariate regression analysis for parameter optimization suggests that for dry cutting, the lowest active and passive forces are obtain with vc = 90.70 m/min, fz = 0.05 mm/tooth and ap = 0.40 mm. The best results for flood-lubricated milling are obtained with vc= 91.51 m/min, fz = 0.05 mm/tooth and ap = 0.46 mm.