Experimental study on cutting force in two-step milling of profile walled surface of titanium alloy

This study establishes an empirical model for a four-flute cylindrical helical end mill, utilizing orthogonal cutting tests on a Ti-6Al-4V block as the machining workpiece. The reliability of the model was confirmed through a titanium alloy side milling experiment. Results demonstrate that the empirical index model for predicting the main cutting force error falls within the range of 4.19 %–10.0 %, providing an effective tool for cutting force prediction. The specific influence distribution trends of cutting parameters, including milling speed, feed per tooth, and depth of cut, on the cutting force through two-step milling of profile walled surface of titanium alloy were analyzed. The results reveal that the milling force in the first step exhibits a discernible upward trend with the increase of feed per tooth and radial depth of cut. Among the cutting parameters employed in the first step, the cutting speed exerts the most significant influence on the cutting force in the second step.