Effects of tool structure factor, cutting orientations, and cutting parameters of double-arc milling cutter on cutting force

Double-arc milling cutter can effectively enhance the workpiece surface quality and is appropriate for finish machining complex surface. This article examines the effects of tool structure factor, two vertical milling orientations, workpiece inclination angle, cutting speed, and feed per tooth on the cutting force in order to thoroughly explore the cutting performance of double-arc milling cutter. Instantaneous effective cutting speed and radius models are established for various cutting orientations and conditions using the parameterized model of double-arc milling cutter. Additionally, a method for characterizing the tool structure factor of double-arc milling cutter is proposed. Three double-arc milling cutters with different structure factor and single factor experiments for milling concave and convex surfaces are designed. The impact of tool structure factor, workpiece inclination angle, cutting orientations, and cutting parameters on cutting force is thoroughly analyzed. Theoretical support is provided for the optimization of tool parameters, cutting orientations, and cutting parameters prior to surface machining.