Optimal Insert Edge Geometry for Minimum Specific Cutting Energy in Face Milling

This paper investigates the effect of the negative insert geometry on the specific cutting energy and explores the parametric space for optimal design to yield minimum specific energy in face milling. Double-sided negative cutting inserts offer many advantages over traditional face milling cutters, including a greater edge strength, improved stability, a higher feed rate, and a better economy. Accordingly, the present study employs the Taguchi robust design methodology to analyze the relative contribution of each geometry parameter of the cutting edge to the specific cutting energy in a face milling process through finite element simulation. A hybrid method consisting of the response surface methodology with a 2nd-order regression model and a genetic algorithm is then used to determine the optimal values of the insert edge geometry. The simulation results show that the specific cutting energy reduces with a larger rake angle of the cutting edge and a greater primary land width, as well as with a higher feed rate. The validity of the simulation results and analysis is confirmed by means of experimental milling trials using inserts fabricated with the optimal edge geometry.