Thesis Topic

Study and generalized modeling of high-feed milling and turn-milling.

Abstract

This PhD thesis focuses on the modeling of high-feed milling and high-feed turn-milling processes applied to the machining of difficult-to-cut materials, particularly titanium alloys used in the aerospace, medical, and defense industries. Although these processes offer significant productivity gains, their behavior remains difficult to predict due to complex tool geometries, variable engagement conditions, and the resulting cutting forces.
The objective of this work is to develop a consistent, general, and physically based modeling framework capable of predicting tool engagement, chip geometry, and cutting forces. A comprehensive methodology is proposed, ranging from the analytical description of the actual tool geometry to the simulation of cutting forces.
A first contribution consists in the development of a generalized cutting-edge modeling approach for high-feed milling tools, combined with both ex-situ 3D scanning and in situ machine-tool measurement techniques. A second contribution addresses uncut chip thickness prediction by considering the actual cutting-edge trajectory, highlighting the limitations of regular milling approximations. New analytical formulations specifically adapted to high-feed machining conditions are proposed.
These developments are then integrated into a mechanistic cutting-force model based on a nonlinear cutting law identified through instrumented milling tests on Ti6Al4V titanium alloy. The results demonstrate the ability of the model to accurately predict cutting forces under various machining conditions. Finally, the methodology is extended to high-feed turn-milling, where the influence of tool-workpiece eccentricity is investigated and experimentally validated.
Overall, this work provides predictive and analytical tools that contribute to the optimization of cutting conditions and to the improvement of productivity in the machining of difficult-to-cut materials.

Doctoral advisors

• Guillaume FROMENTIN - Director
• Jean-Baptiste GUYON
• Fabien VIPREY

Partner

• MBDA

Funding

• French Ministry of Higher Education and Research (MESR)

Start

1st of September 2023

End

31th of August 2026