3 rd International Workshop on Structural Mechanics and Materials -IWSMM24-

Study of influence of feed rate and depth of cut on cutting forces

in ball end milling of Aluminum alloy 7075-T6: using a
mechanistic approach
Mekentichi Sifeddinea,*, Benmohammed Brahimb
a,
* Product Research Laboratory (LRP),University Batna 2 - Mostefa Benboulaid, Faculty of Technology,
Mechanical Engineering Department, 53 Route de Constantine, Fésdis, Batna 05078, Algeria.

b
Product Research Laboratory (LRP),University Batna 2 - Mostefa Benboulaid, Faculty of Technology,
Mechanical Engineering Department, 53 Route de Constantine, Fésdis, Batna 05078, Algeria.

ARTICLE INFO ABSTRACT

Article history: This paper investigates the influence of feed rate and depth of cut on cutting
Received -
forces in ball end milling of AL7075 T6, a high-strength aluminum alloy
Accepted commonly used in aerospace and machinery applications. To accurately
Keywords: predict these forces, a dedicated mechanistic model is developed, taking into
Cutting forces account the complex interactions between the tool geometry, the cutting
Ball end milling parameters and the material properties.
Mechanistic approach The proposed model is then employed in a comprehensive simulation study
Numerical simulations to analyze the variation of cutting forces under different feed rate and depth
work piece materials: of cut settings. This study aims to:
Aluminum alloy-T6  Quantify the individual and combined effects of feed rate and depth
of cut on cutting forces acting in different directions (axial, radial
and tangential).
 Identify optimal cutting parameter combinations that minimize
cutting forces, leading to improve process efficiency and to reduce
the tool wear.
The obtained simulation results leads that an understanding of cutting forces
in ball end milling is essential for improving machining efficiency and
product quality, especially when varying cutting conditions. Overall, this
work stands as a valuable resource for researchers, engineers and industries
conduct them to improve precision and efficiency in ball end milling
processes.

1. INTRODUCTION
The machining of high-strength aluminum alloys demands a meticulous understanding of the complex
relationship between machining parameters and resulting cutting forces, [1].

_____________________
a,* MEKENTICHI Sifeddine, E-mail address: s.mekentichi@univ-batna2.dz
Tel : + 213 674187057
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In this context, the present study aims to explore the complex phenomena of the AL 7075-T6 ball end
milling process, a renowned material for its exceptional strength-to-weight ratio and a widespread
material used in the aerospace and the important engineering applications.
The objectives of this research are: firstly, to present a comprehensive mechanistic model that
accurately characterizes the cutting forces in ball end milling, and secondly, to systematically
investigate the individual and combined effects of feed rate and depth of cut on these cutting forces.
The proposed mechanistic force model serves as a tool for predicting and optimizing cutting forces in
the machining of aluminum alloy AL 7075-T6, contributing to the efficiency and precision of
manufacturing processes.
In order to achieve these objectives, this research employs a rigorous validation process, comparing
the predictions of the mechanistic force model with experimental cutting forces data. This validation is
crucial to ensuring the accuracy and practical relevance of the cutting force model, bridging the gap
between the theoretical formulations and the real-world machining scenarios.
This study lies not only in its contribution to the fundamental understanding of cutting forces in ball
end milling process but also in its practical implications for industries and engineers seeking to
enhance the efficiency and reliability of machining processes involving high-strength aluminum
alloys. By unravelling the complex relationships between the machining parameters and the cutting
forces, this research aims to provide valuable insights for optimizing the machining of AL 7075-T6
alloy, and ultimately permit as to advance the state-of-the-art in a precision manufacturing.

2. MECHANISTIC APPROACH
The mechanistic approach basis is to assume that the cutting force components Fc and Fa are
proportional to the chip section (A), [2]:

 Fa  ka .w.t1
 (1)
 Fn  kn .w.t1
We suppose that the cutting tool and the work piece are rigid. The used machined material is an
aluminum alloy (7075-T6), Table 1.

Table 1. Representative ks values for selected work piece materials, [2]

Material k s (N/mm2 ) Material k s (N/mm2 )
Gray cast iron 1500 Ni-based Inconel X 3400
1020 carbon steel 2100 Ni-based Udimet 500 3500
1035 carbon steel 2300 Co-based L605 3500
1045 carbon steel 2600 Ti (6AL-4V) 2000
302 stainless steel 2700 AL 7075-T6 850
4140/5140 alloy steel 2800 AL 6061-T6 750

We could express the cutting force on any cutting edge of the ball milling tool, in function of a chip
section (A) and a specific cutting pressure (k s ), as:

F  ks .A  ks .w.t1 (2)

The cutting force components and specific coefficients in the tangential, normal and axial directions
are determined for each axial slice of the ball milling tool, “Fig. (1)”:
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Up-milling process

Fig 1. Geometry for ball milling process and cutting force components

From the geometry “Fig. (1)” we could express the components of the cutting force as follow:

 Ft  k s .sin( )  kt .w.t1

 Fn  k s .cos(k )  kn .w.t1
'
(3)

 Fa  k s .sin(k )  ka .w.t1
'

With:
kt  k s .sin(  )

kn  ks .cos( k') (4)
k  k .sin( k')
 a s

We obtain the following cutting force components:

 Ft  kt .w.t1

 Fn  kn .w.t1 (5)
 F  k .w.t
 a a 1

The projection of the cutting force components on the fixed x-y-z coordinate mark depends on the two
parameters: (ϕ) the tool rotation angle and (k)’ the axial immersion angle, for both the selected tool’s
tooth and slice. The relationships of the cutting forces could be written as follow:
 Fx   cos(a ) sin(a ).sin(k ')  sin(a ).cos(k ')   Ft 
     (6)
 Fy    sin(a )  cos(a ).sin(k ') cos(a ).cos(k ')   Fn 
   0  cos(k ')  sin(k ')  F 
 Fz    a

In relation (6) k’ is equal to (90°). The force projections following x, y and z directions are given by
relation (7):

 Fx   cos(a ) sin(a ) 0   Ft 
    
 Fy    sin(a )  cos(a ) 0   Fn  (7)
   0 1  Fa 
 Fz   0

3. SIMULATION RESULTS
In this study, the cutting forces were evaluated for a 30% radial immersion in up-milling process with
a zero start angle and an exit angle of (66.4°) by using 5 mm axial depth of cut. The work piece is an
aluminium alloy AL7075-T6 [2], and the cutting force coefficients were assumed to be equal for both
the four tooth of the used ball end mill.
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We used the following cutting parameters in the simulation, Table 2:

Table 2 - Cutting parameters values

Cutting parameters Values
Number of teeth 4

Helix angle 45 deg

Force angle 60 deg

Feed per tooth 0.1 mm/tooth

Tool diameter 12 mm

Spindle speed 15000 rpm

850 N/mm2
Specific force (AL 7075-T6)

“Fig. (2)” represent the components of cutting forces as a function of time:

Fig 2. Ball milling cutting forces for AL7075-T6

“Fig. (3)” represent the resultant cutting force expressed in relation (8):

F  Fx2  Fy2  Fz2 (8)

Fig 3. Ball end milling resultant cutting force for AL7075-T6

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Due to variations in the ball surface normal angle, cutting forces differ along all the three axes. The
engagement of the tool, with the work piece at different points on its spherical surface cause, changes
in the ball surface normal angle, leading to varying the axial, the tangential and the radial components
of the cutting force.

4. THE INFLUENCE OF THE FEED RATE ON THE CUTTING FORCES

IN BALL END MILLING

We have studied the effects of three different feed rates on the cutting forces (“Fig. (4)”, “Fig. (5)” and
“Fig. (6)”). The cutting forces are significantly reduced when a feed rate of 0.1 mm/rev/tooth is
applied. On the other hand, because of the bigger cutting section, increasing the feed rate to 0.15
mm/rev/tooth and 0.2 mm/rev/tooth causes an obvious increase in the values of cutting forces.

 Feed rate: ft = 0.1 mm/rev/tooth, “Fig. (4)”:

Fig 4. Influence of the feed rate on milling force: ft = 0.1 mm/rev/tooth

 Feed rate: ft = 0.15 mm/rev/tooth, “Fig. (5)”:

Fig 5. Influence of the feed rate on milling force: ft = 0.15 mm/rev/tooth

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 Feed rate: ft=0.2 mm/rev/tooth, “Fig. (6)”:

Fig 6. Influence of the feed rate on milling force: ft = 0.2 mm/rev/tooth

There is a significant impact of feed rate on cutting forces “Fig. (7)”. Understanding this relationship
is crucial for optimizing machining operations. Our study specifically examined feed rates of 0.1, 0.15
and 0.2 mm/rev/tooth, demonstrating that the feed rate plays an important role in machining process
by showing the different variations in cutting force. With this important information, the productivity
is increased and the life of cutting tools is extended.

(mm/rev/tooth)

Fig 7. Variation of cutting forces with different feed rates (0.1, 0.15 and 0.2 mm/rev/tooth)

The histogram clearly shows that there is a direct link between feed rate and cutting forces in ball end
milling process. This understanding is crucial for process optimization, allowing practitioners to select
feed rates that balance machining efficiency with tool life and minimizing the risk of overloading the
machine or exceeding tool capabilities

5. THE INFLUENCE OF THE AXIAL CUTTING DEPTH ON THE CUTTING

FORCES IN BALL END MILLING

We selected three different values of axial depth of cut for our study (“Fig. (8)”, “Fig. (9)” and “Fig.
(10)”). It is important to note that cutting forces are significantly reduced when using an axial depth of
cut of 2 mm (b = 2 mm). However, increasing the axial depth of cut to 4 mm and to 6 mm leads to an
important increasing in cutting forces due to the larger cutting section.
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 Axial depth of cut: b = 2 mm, “Fig. (8)”:

Fig 8. Influence of axial cutting depth on milling forces: b = 2 mm

 Axial depth of cut: b = 4 mm, “Fig. (9)”:

Fig 9. Influence of axial cutting depth on milling forces: b = 4 mm

 Axial depth of cut: b = 6 mm, “Fig. (10)”:

Fig 10. Influence of axial cutting depth on milling forces: b = 6 mm

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Cutting forces VS Axial depth of cut

Axial depth of cut (mm)

Fig 11. Variation of cutting forces with axial depth of cut (2 mm, 4 mm and 6 mm)

The axial depth of cut stands out as a pivotal factor influencing the trajectory of cutting forces. This
understanding provides valuable insights for optimizing machining conditions, offering a nuanced
perspective on the intricate interplay between the axial depth of cut and cutting forces.

6. CONCLUSION
 The study investigates the influence of feed rate and axial depth of cut on cutting forces in ball
end milling of Alu7075 T-6 alloy.
 The simulation results indicate a direct correlation between feed rate and cutting forces,
highlighting the importance of selecting appropriate feed rates for balancing machining
efficiency and tool life. Understanding this relationship is essential for process optimization,
aiding in the selection of parameters to minimize machine overload and ensure tool capabilities
are not exceeded.
 The axial depth of cut stands out as a pivotal factor influencing the trajectory of cutting forces.
This understanding provides valuable insights for optimizing machining conditions, offering a
nuanced perspective on the intricate interplay between the axial depth of cut and cutting forces.
 The mechanistic approach employed in this study provides a nuanced understanding of the
interplay between machining parameters and cutting forces, facilitating informed decision-
making in manufacturing processes.

7. REFERENCES

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[2] T. L. Schmitz, K. S. Smith (2009) Machining Dynamics Frequency Response to Improved
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[3] S. Smith, J.Tlusty (1991) An Overview of Modeling and Simulation of the Milling Process,
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Journal of Engineering for Industry, 113: 169–175, 1991; doi.org/10.1115/1.2899674.

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