Research Information System
KORKUT İ. (Executive), BAYRAM B. S.
Project Supported by Higher Education Institutions, 2021 - 2022
Milling operations
are an important manufacturing method that is frequently used in many areas of
production such as defense, automobile and medical industries. The milling
method is a process in which the final part is given its final shape by cutting
from a whole part and removing chips. The performance of this method and the
quality of the produced part are directly related to the stability of the
cutting process. It is important to understand the dynamics of milling to
improve the stability of the cutting process. A mechanical model has been
developed to predict the cutting forces that affect the stability of the
milling process within the scope of this project. The specific shear
coefficients used in the estimation model were calculated based on the
optimized shear force data and based on the average shear force concept.
Fourier approximation method was used to optimize the force data in sinusoidal
form. Three repetitive milling experiments were carried out with different
predetermined feed rate parameters, constant cutting speed and axial depth for
each feed value in order to calculate the cutting coefficients. AISI 4140
tempered steel with an average hardness of 304 HB was chosen as the workpiece
for the milling experiments. As the cutting tool, end mill with 38° helix angle
and 9.5 mm diameter made of AlCrN coated tungsten carbide (WC) alloy was used.
The force estimates made with the model presented in the study were compared
with the experimental measurements, and it was seen that the estimates were in
agreement with the experimental measurements in the 80-90% accuracy range.