The effects of cutting parameters and tool geometry on cutting forces and tool wear in milling high-density fiberboard with ceramic cutting tools

In this paper, the effects of cutting parameters and tool geometry on cutting forces and tool wear when up-milling high-density fiberboard with alumina ceramic cutting tools were investigated. Under the condition of the same feed per tooth, average chip thickness, and clearance angle, the results shown are as follows: first, the tangential forces F (t) and normal forces F (r) at low-speed cutting were higher than those at high-speed cutting, but increased slowly with the increase of cutting length and rake angle decrease. Second, increased cutting speed and decreased rake angle had a great effect on rake face wear. Third, the wear patterns of tool wear were rake wear and flank wear, which included pull-out of grain, flaking, and chipping. The wear mechanisms were adhesive wear and abrasive wear. Finally, at low-speed cutting, the cutting tools with bigger rake angle can be selected to reduce the energy consumption of machine tools. The tools with smaller rake angle can be used for high-speed cutting to improve tool life and productivity of processing.