Analytical and experimental investigations on thread milling forces in titanium alloy

This study deals with the thread milling process that is considered a complex machining technique due to its elaborated tool geometry and its tridimensional tool trajectory. It needed advanced research on the threading process which has not been much studied. Previous studies focused on geometrical modeling or mechanistic modeling of the thread milling process. There is a need for a better understanding of parameter effects to accomplish a model that tends to be more realistic and includes local parameters. This investigation does the analysis of thread milling parameters: thread geometry, cutting conditions and tool angles, which can be applied to the tool optimization. The cutting forces and torque were measured and representative values of its variation were calculated and analyzed as response of the experiments. A geometrical analysis and an analysis of variance were employed for determining the influence of the factors and based on the results, it is proposed a physical understanding of the process.

► Understanding of geometry and mechanics in thread milling and nomenclature. ► Force and torque acquisition on titanium alloy using rotating dynamometer. ► Definition of parameters, referential frames and significant criteria for analysis. ► Effects of feed, tool geometry and thread geometry on outputs using ANOVA. ► Results indicate flute angle optimization and machining parameters recommendations.