Analysis of the Effect of Machining Parameters on the Cutting Tool Deflection in Curved Surface Machining

The aim of this study is to investigate the impact of machining parameters on the deflection of a cutting tool (i.e., end mill) in the milling of a surface with a curvilinear profile. Test samples were made of aluminium alloy EN AW-7075 T651. Experiments were conducted using the Gocator 2530 laser line profile sensor for real-time measurement of dynamic tool displacement with an inspection speed up to 10 kHz at resolution ranging from 0.028 to 0.054 mm. Response surface methodology was used. Five main technological factors were analysed: cutting speed, feed per tooth (cutting parameters), amplitude, term (curvilinear profile parameters), and the number of flutes (end mill parameter). Obtained data were filtered and visualised as 3D plots. The results showed that cutting speed and amplitude had the greatest impact on tool deflection, while feed per tooth also played a significant role in process stability. In particular, the use of tools with a higher number of flutes led to a considerable reduction in tool deflection, confirming their positive effect on the stability of the machining process. These findings may serve as a basis for the optimisation of machining parameters by taking into account the dynamic deformation of cutting tools.