Development of an analytical model to investigate the effect of tool geometry and cutting parameters on the milling performance of Inconel 718

This research proposes a new analytical method to predict cutting forces of end milling considering various tool geometry and cutting parameters, aiming to achieve enhanced stability in machining processes and superior quality in machined surfaces. The end-milling process was modeled using the unequal shear zone theory of oblique cutting, where the helical cutting edges were discretized into multiple oblique cutting edges, and the coordinate transformation method was employed to analyze the geometric and force relationships among them. Then, the influence of helix angles on cutting force, machined surface quality, tool life, and wear patterns in the milling process of Inconel 718 was investigated. These findings provide valuable insights that can be utilized to optimize the design of variable helix tools.