Analysis of force patterns and tool life in milling operations

The paper describes the practical effects of the operating parameters in the milling operation. Experiments have been conducted to measure cutting force and tool life under dry conditions. Based on the experimental results, three mathematical models have been developed: Force, TLife and Force/TLife. Further analyses have been conducted on the cutting force patterns: seasonal pattern and nonlinear trend. A process optimisation that is based on the minimum production cost has been applied to relate Force model, TLife model and machinability criteria, such as power consumption, cutting parameters and surface roughness.