Milling-Force Prediction Model for 304 Stainless Steel Considering Tool Wear

Abstract

The high-performance alloy, 304 stainless steel, is widely used in various industries. However, its material properties lead to severe tool wear during milling processes, significantly increasing milling force and adversely impacting machining quality and efficiency. Consequently, an accurate milling-force model is crucial for guiding the formulation and optimization of machining parameters. This paper presents a milling-force prediction model for 304 stainless steel that incorporates the effect of tool wear, based on the mechanistic modeling approach. Side-milling experiments on 304 stainless steel were conducted to analyze the relationship between milling force and tool wear, identify the model coefficients, and validate the prediction accuracy of the milling-force model. The results demonstrate that the model accurately predicts the milling forces of worn tools while side milling 304 stainless steel under various machining parameters and tool wear conditions.