Cutting parameters and tool geometry selection for plunge milling - Analysis of cutting forces at the bottom of deep titanium workpieces

Plunge milling is a machining process recognized to be efficient for roughing deep workpieces. This due the distribution of cutting forces on tool. Important axial and reduced radial lead more rigidity, eventually productivity. It commonly used in case hard cut materials, like titanium alloys. However, plunge can exhibit problem at end plunging phase, which increase forces. Within this paper, study considers wet applied Ti-6Al−4 V alloy, that most generally alloy wide range applications. The authors investigate effects geometrical parameters amplification bottom pockets. shows augmentation chip cross-section cause forces, model set up so as predict enlargement depending several parameters. results indicate entering angle nose radius insert are main influential Furthermore, was found parameters, principal parameter offset. Thus, proper type should carefully chosen order avoid high levels workpieces operations.