Experimental research on micro-milling force of a single-crystal nickel-based superalloy

In the milling process of difficult-to-machine materials using micro-milling tools, the cutting thickness is gradually increased along the radial feed direction, and the plow and the shear zone are present at the same time. In addition, due to the influence of the spiral angle and the wear of the tool, the micro-milling force cannot be ignored. According to the characteristics of micro-milling, a mathematical model for micro-milling force is improved and established based on a mechanical method, and a finite element simulation of the micro-milling force is realized. Through the construction of a micro-milling force testing platform, the micro-milling force of a single-crystal nickel-based superalloy DD98 material is measured and verified. The influences of different performance materials on the micro-milling force are compared, and the influence rule for the cutting parameters on the milling force is obtained. The results show that the values of the micro-milling force of the established theoretical model, the simulated milling force and the experimental milling force are close, and the error is small. This work provides a reference for the prediction and measurement of milling forces, and it has good theoretical and practical significance.