Influence of Cutting-Edge Microgeometry on Cutting Forces in High-Speed Milling of 7075 Aluminum Alloy

In the present study, the impact of cutting-edge microgeometry on the cutting forces in the finish milling of a 7075-aluminium alloy was analysed. The influence of selected values of the rounding radius of cutting edge, and the size of the margin width, on the cutting-force parameters was analysed. Experimental tests were carried out for different cross-sectional values of the cutting layer, changing the feed per tooth and radial infeed parameters. An analysis of the various statistical parameters of the force signal was performed. Experimental mathematical models of the relationship of the force parameters to the radius of the rounded cutting edge and the width of the margin were developed. The cutting forces were found to be most strongly influenced by the width of the margin and, to a minor extent, by the rounding radius of the cutting edge. It was proved that the effect of margin width is linear, and the effect of radius R is nonlinear and nonmonotonic. The minimum cutting force was shown to be for the radius of rounded cutting edge of about 15–20 micrometres. The proposed model is the basis for further work on innovative cutter geometries for aluminium-finishing milling.