Prediction of Cutting Forces in Face Milling

Abstract

A comprehensive understanding of cutting forces is crucial for managing tool life, improving surface finish, and ensuring process stability. Accurate modeling of these forces, combined with real-time monitoring, enhances machining efficiency and helps reduce production costs. The three main cutting forces, radial, tangential, and axial, can be further broken down into different components, which vary based on factors like cutting geometry, material properties, and machining conditions. In conclusion, understanding and managing milling cutting forces is essential for achieving optimal performance in milling operations. By adjusting cutting speed, feed rate, and depth of cut, one can achieve reduced tool wear, improved surface finish, and enhanced overall efficiency of the milling process. In this study, experiments were carried out using the SWEDEN Model Milling Machine at the Central Workshop of SGSITS Indore. To analyze the data, Response Surface Methodology (RSM) was applied in Minitab to generate main effects plots, which are critical for identifying the optimal input parameters for force prediction and MRR maximization. Based on the force analysis of face milling conducted, a cutting force model has been developed as part of this study. Theoretical and practical data show that while the force FX is hostile toward the conclusion of the cut, the force FY has comparatively small negative values at the start of the cut. The findings of both theoretical and experimental studies indicate that altering the depth of cut significantly affects FX and FY while having a minor effect on FZ. The cutter's angular rotation value at which FX and FY are zero is almost constant regardless of variations in the depth of cut. While the percent error in FZ forecast tends to be bigger, the percent error in FX and FY spans from 0 to 12%.