Balancing the transverse cutting force during inclined milling and effect on tool wear: application to Ti6Al4V

The present article studies the effect on cutter wear of balancing transverse cutting forces during inclined milling applied to a titanium alloy (Ti6Al4V). Indeed, this method is advantageous as it helps reduce vibrations as also the amplitude of such forces thanks to balancing. These observations provide the means to enhance cutting conditions and thus boost productivity when roughing. The method was first validated on Ti6Al4V titanium alloy. A model was then proposed to estimate the maximum axial cutting force at angular positions 0 and p. A wear test was then conducted and notching, flaking and flank types of wear were observed as being most representative. Roughness measurements were made throughout the wear test as also measurements of cutting forces with a new cutter and the worn cutter to provide a comparison. The cutting forces remained acceptable and the roughness values measured remained below the criteria generally retained for roughing. The improvements obtained in terms of extended tool life when using this method were extremely significant since under the same cutting conditions flat milling gave a lifetime of 2.03 min while when machining with balancing of the transverse cutting forces this was extended to 23.6 min.