An experimental study of the response characteristics of end milling operations and their finite element simulation

The present study investigates the effect of milling parameters on cutting forces and performance characteristics in end mill operations using two different types of end milling tools. The end milling experiments were performed on AA7075-T6 grade aluminium alloy using a vertical milling machine fitted with a Kistler dynamometer to acquire the data of cutting forces during the milling operation. A matrix of process parameters was created by varying spindle rotational speed in the range of 500–1200 rpm while the feed rate was kept between 10 and 30 mm/min, keeping a maximum depth of cut of 4 mm. The data obtained from the experimental results were analysed and validated by simulation using the DEFORM-3D software facility. The experimental results reflect that with the increase in cutting speed, the cutting force first increases and then decreases, while an increase in feed rate enhances the cutting forces. The combination of high cutting speed with low feed rate was found to be suitable as the force required in this case exhibits a minimum to achieve both efficiency and machinability for a tool. Validated experimental results can be useful for finding new combinations of parameters in the defined parameter range for milling applications.