Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth a(p)) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on S(a) (surface arithmetic mean deviation) and S(q) (surface root mean square deviation) from high to low level is the v, the f, and the a(p). When v = 600 m/min, a(p) = 0.5 mm, f = 0.1 mm/r, S(a) and S(q) are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, F(x) reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases F(x). The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool’s life. The optimal milling processing parameters in this paper are the v = 600 m/min, a(p) = 0.5 mm, and f = 0.1 mm/r.