Analyzing the effect of cutting parameters and tool nose radius on forces, machining power and tool life in face milling of ductile iron and validation using finite element analysis

Abstract In the present study, the effect of cutting speed, feed rate, and tool nose radius on the forces, cutting power and tool life has been investigated in machining ductile iron. Face milling inserts with 0.8 mm and 2 mm corner radii were tested at three different cutting speeds and feed rates. The experiments were conducted using a full factorial design method and the Analysis of Variance (ANOVA) technique was used to determine the significance of each variable that is responsible for the variation in forces and machining power. AdvantEdge finite element analysis software was used to study the stress zones and temperature distribution on the cutting edge. The study shows that when the feed rate is increased, there is a linear increase in the radial (Fx) and cutting (Fy) forces. The contribution of feed rate on Fx and Fy forces was around 80% and 87%, respectively. However, with a significance of around 17%, the effect of the tool nose radius was pronounced more in the axial direction (Fz force). The finite element analysis showed higher temperature and stress regions in the nose radius zone of the tool with 2 mm corner radius. The lesser contact area between the tool and workpiece of the insert with 0.8 mm nose radius resulted in lower axial force, lower friction, and increased tool life by around 57%.