Prediction of cutting forces and vibration in titanium alloy milling using a toroidal cutter

Titanium alloys are frequently used when a high strength-to-weight ratio and good hot hardness, corrosion resistance, and fatigue properties are needed. One of the most widely used of these alloys is Ti-6Al-4V. However, titanium alloys with these characteristics generally have poor machinability and tend to cause the machine-tool-workpiece-fixture system to vibrate. In this work, a model for predicting the cutting forces in milling is adapted for milling with toroidal cutters, and the dynamic effects of machining are included in the model. The cutting constants are determined in milling experiments, and the dynamic parameters used in the vibration model are determined in modal tests. By including cutting vibration in the model, the vibration behavior during milling can be understood and the cutting forces in real milling processes can be better simulated.