EFFECTS OF CUTTING PARAMETERS AND TOOL-PATH STRATEGIES ON TOOL ACCELERATION IN BALL-END MILLING

Abstract

The determination of the cutting-parameter values that cause increases in vibration values is important to minimize the errors that can occur. Thus, the first aim of this study was to investigate the optimum cutting-parameter values and tool-path strategies in ball-end milling of the EN X40CrMoV5-1 tool steel with three coated cutters using the Taguchi method. The parameters taken into consideration are the cutting speed, feed rate, step over and tool-path strategies. The second aim of the study, a model for the tool acceleration as a function of the cutting parameters, was obtained using the response-surface methodology (RSM). As a result, the most effective parameter within the selected cutting parameters and cutting strategies for both inclined surfaces and different coatings was the step over. In terms of tool coatings, the most deteriorating coating for the tool acceleration on both inclined surfaces was the TiC coating. In addition, the response-surface methodology is employed to predict the tool-vibration values depending on the cutting parameters and tool-path strategy. The model generated gives highly accurate results.