Influence of the Number of Inserts Used for Face Milling on Cutting Forces and Surface Roughness

Abstract

This article examines the effect of the number of inserts in a milling head on cutting forces during machining and the resulting surface roughness. An experimental study was used to compare results using different insert configurations while maintaining a constant feed per tooth. The resulting cutting forces and surface roughness were analyzed and discussed in the context of the optimal setting of cutting conditions. It was found that a reduced number of inserts does not necessarily lead to a reduction in cutting forces during machining and that while maintaining the feed per tooth with a reduced number of inserts, the roughness is not significantly affected. An unexpected result was that inserts can differ in terms of the surface quality achieved. This research also shows that individual inserts can vary substantially in the force load they generate, a phenomenon that can be attributed to their dimensional differences. This study provides valuable insights for industrial applications that require precision machining concerning cutting forces and surface quality. It can potentially improve the efficiency and quality of machining in industrial applications.