Simulation and experiment study on cutting force of coated tool milling natural marble

The simulation of coated tool milling natural marble is constructed based on Deform-3D. The influence mechanism of machining parameters on cutting force is analyzed. The results show that the error between cutting forces of simulation and experiment is within 10%, suggesting the reliability of the simulation results. According to the study, the cutting force decreases along with the increase of spindle speed while the downtrend of cutting force slows down because of workpiece work-hardening when spindle speed reaches around 3000-5000 r/min; the cutting force linearly increases with the changes of cutting depth due to the increase of axial cutting quantity; the cutting force increases as the increase of feed speed below 3000 mm/min. Once feed speed reaches to 3000 mm/min, the brittle-ductile transition appears, resulting in redistribution on the surface which decreases the real cutting force; The empirical equation of cutting force is obtained through experimental data, which indicated that large spindle speed and feed speed, small cutting depth can reduce cutting force; the appearance of brittle-ductile transition will increase the surface quality and thus improve cutting performance of coated tool.DOI: http://dx.doi.org/10.5755/j01.mech.22.4.16160