Three-dimensional dynamic cutting forces prediction model during micro-milling nickel-based superalloy

Nowadays, there are urgent demands of micro structure/parts which have high strength in high-temperature environment in the fields such as aerospace, energy, power, biomedical, etc. Nickel-based superalloy with high strength and high hardness under high temperature is the suitable material for manufacturing this kind of micro parts. Aimed at the problem of the complicated cutting force variation rule when micro-end milling nickel-based superalloy, the cutting forces model during micro-end milling of nickel-based superalloy processing is studied. Firstly, micro-end milling hole experiments are carried out to establish the radical run-out prediction model of cutting edge, which lays the foundation for establishing the cutting thickness calculation model during micro-end milling. Then, based on the minimum cutting thickness value, micro-end milling of nickel-based superalloy process is divided into two different cutting processes: shear-dominant regime cutting process and ploughing-dominant regime cutting process. Moreover, cutting forces prediction model during shear-dominant regime cutting process is developed based on the cutting forces in proportion to cutting layer area, which takes the effect of ploughing into account. Meanwhile, cutting forces prediction model during ploughing-dominant regime cutting process is developed based on the cutting force in proportion to interference volume between the flank surface of cutting tool and the workpiece. The experiment results verify that the cutting forces prediction results and experiment results are well matched.