Analysis of the Effect of Feed on Chip Size Ratio and Cutting Forces in Face Milling for Various Cutting Speeds

Face milling is one of the most common machining processes used for the production of high quality flat surfaces. Another important feature of the process is the high material removal rate that can be achieved, or in the case of milling performed at one pass, the high surface rate. Surface rate is increased by increasing feed and cutting speed; both are bound by technological limitations and are limited to rather small variations, especially cutting speed. In finishing face milling, if feed per tooth is increased, subsequently the shape of the chip cross section is altered. This results in the change of the loads of the cutting edges, which influences the cutting forces and process efficiency. In this study, an experimental investigation is carried out in order to determine the influence of feed on chip size ratio. For this purpose, five different values of feed, at two different cutting speeds are tested for face milling. It is concluded that an increase in feed from 0.1 to 1.6 mm results in eight-fold increase of cutting force Fc while surface rate proportionally increases 16 times and specific cutting force only 0.5 times.

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