Influence of cutting ratio and tool macro geometry on process characteristics and workpiece conditions in face milling

This paper presents the influences of the inverse cutting ratio (width-to-thickness b/h<1) and the macro cutting geometry on the chip formation, milling forces, tool deflection, as well as on the workpiece surface integrity in face milling. The investigations are based on the DoE method using finite element simulation and practical experiments. A significant decrease of the cutting force by up to 65%, was achieved using inverse cutting ratio. Accordingly, the mechanical tool deflection from its axis was reduced. At the same time, the residual tensile stresses of the workpiece surface increase applying the inverse cutting ratio.