Digitized Stress Function-Based Feed Rate Scheduling for Prevention of Mesoscale Tool Breakage during Milling Hardened Steel

In this article, a digitized stress function-based feed rate scheduling algorithm is formulated for the prevention of tool breakage while having an optimum material removal in mesoscale rough milling hardened steel. Instead setting limits to cutting forces and rates, presented method regulates tool’s stresses. A 3D coupled Eulerian-Lagrangian finite element (FEM) model used simulate chip flow-based according rotation during Maximum uncut thickness engaging angle identified as fundamental driving factors down configuration. Furthermore, multiple linear regression formed digitize with two major scheduling. The rates each segment along path can be obtained through models model. validated experiments paths arc segments. series experimental validations, demonstrated capability reducing machining time eliminating breakages.