Prediction and experimental validation of cutting forces in ball end milling of aluminum 7075-T6 alloy
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1
Product Research Laboratory (LRP), University Batna 2 - Mostefa Benboulaid, Faculty of Technology, Mechanical Engineering Department, 53 Route de Constantine, Fésdis, Batna 05078, Algeria.
2
ESTA, School of Business and Technology, 3 Rue Fréry-CS 50199 90004 Belfort Cedex, France.
3
Higher National School of Renewable Energies, Environment & Sustainable Development, Constantine road, Fesdis, Batna ,05078, Algeria.
Corresponding author
Mekentichi Sif-Eddine Sif-Eddine
Product Research Laboratory (LRP), University Batna 2 - Mostefa Benboulaid, Faculty of Technology, Mechanical Engineering Department, 53 Route de Constantine, Fésdis, Batna 05078, Algeria.
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ABSTRACT
This study presents the development and validation of a hybrid cutting force prediction model for ball end milling of aluminum 7075-T6 alloy. The model combines a mechanistic approach with a specific cutting force coefficient (Ks=850 N/mm²) sourced from experimental literature. Cutting forces in the x, y, and z directions are predicted by integrating differential force components with tool geometry and machining parameters. Experimental validation was performed under dry conditions at a spindle speed of 15,000 rpm. In the x-direction, the simulated force was 162.4 N versus an experimental force of 215.4 N; in the y and z-directions, predicted values (65.2 N and 25.3 N) closely matched experimental forces (74.3 N and 28.2 N), respectively. The corresponding mean absolute errors were 18.2% (x), 4.5% (y), and 3.3% (z). The higher error in the x direction highlights limitations in modeling tangential force dynamics, while the y and z predictions align closely with experimental data. Leveraging the experimentally derived Ks, the proposed model offers a practical tool for optimizing machining processes in the aerospace sector, with potential for further refinement in tangential force modeling.