Side Oscillation Milling: Modeling, Analysis, and Compensation of Cutting Forces Through Feed Optimization

This article presents an analysis and the modeling of cutting forces in the process of oscillation milling of side surfaces of workpieces made of hardened steel. In addition, the impact of the oscillation machining method on cutting forces was analyzed, taking into account feed optimization. A sinusoidal function was used to describe the trajectory of the tool in order to induce the oscillatory motion. The study is based on a set of 34 cutting tests using four end-mill cutters, each characterized by a unique combination of feed rate and sinusoidal downward and upward angles. This constitutes a novel approach to sine wave period selection. Empirical mathematical models of the cutting forces were developed using the response surface method. The results demonstrate that the sinusoidal trajectory of the tool movement, together with optimization of the feed rate, leads to a reduction in fluctuations and the stabilization of cutting forces, and an approximately 30% increase in the efficiency of this machining process.