Cutting Forces and Vibrations During Ball End Milling of Inclined Surfaces

This work concentrates on the analysis of cutting forces and vibrations generated during ball end milling process with variable surface inclination angle (α). The cutting force and tool's displacements (vibrations) model including surface inclination was formulated. Experiments were carried out on hardened alloy steel X155CrVMo12-1 with sintered carbide (TiAlN coating) monolithic tool. Instantaneous values of cutting forces were measured in the range of variable feed per tooth (fz) and surface inclination angle (α) values. The shear (Kic) and edge (Kie) coefficients in function of analyzed factors were determined using the measured cutting force signals as an input data. The research revealed that cutting forces and vibrations are strongly affected by the surface inclination, both in quantitative and qualitative aspect. This observation is also confirmed by the developed model.