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1 2015

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Cutting Force Reduction in The Milling of Aluminum Alloys with Serrated Cutting Tool Edges

Rekers S., Auerbach T., Veselovac D., Klocke F.

Journal of Machine Engineering

2015

Vol. 15, No. 4

27--36

Structural components for aerospace industry are in most cases milled from solid. Usually more than 80 % of the bulk material is removed by milling processes in order to obtain the parts final shape. Due to economic aspects, high material removal rates are desired to reduce cost intensive machine cycle times. In order to meet high process design demands, optimized cutting forces at maximized material removal rates are of crucial interest. These are especially depending on the work piece material to be machined, the cutter work piece engagement conditions as well as the milling cutters geometry. The usage of milling tools with serrated cutting edge geometries enables a significant reduction of cutting forces. In this article, cutting forces during milling aluminum alloys using different serration geometries and engagement conditions are investigated. At first, a generic cutting force model is introduced. The required model parameters are approximated for the machined material by subsequent milling tests employing non-serrated cutters. In a second step, a model is presented allowing a time-domain simulation to obtain cutting force variations for cutters with serrated cutting edges. Finally, experimental data for different serrated cutters are compared with the simulated predictions.