Study on ploughing phenomena in tool flank face workpiece interface including tool wear effect during ball end milling

Abstract

Ploughing phenomena occurring during precise machining processes affect the formation of surface finish and progress of tool wear. Therefore, this study presents an evaluation of ploughing phenomenon by studying the ploughing forces in tool flank face workpiece interface during precise ball end milling of AISI L6 alloy steel. Developed original model of ploughing forces involved the effect of minimum uncut chip thickness hmin and ploughing volume during ball-end milling. Estimated ploughing forces are sensitive to variations of surface inclinations and progressing tool wear. Moreover, intense growth of ploughing force during milling with worn tool is affected by irregular and non-circular profile of worn cutting edge below the stagnant point, and by the appearance of attrition and micro-grooves on tool flank face.