Effect of cutting parameters on cutting performance of nodular cast iron in ultra-fine-pitched milling

Nodular cast iron is widely used to manufacture various important mechanical components due to the comprehensive mechanical properties and relatively low cost. However, the machining efficiency and surface quality of nodular cast iron are difficult to be guaranteed because of the unstable cutting processing and severe tool wear. In this study, the effect of cutting parameters on the cutting performance of nodular cast iron in large size plane ultra-fine-pitched milling was systematically investigated. The dynamic milling force model showed that the milling force of multiple cutting edges was superimposed by the milling force of each cutting edge. When the number of cutting edges varied from 3 to 12, the cutting force increased linearly, while the average cutting force per tooth was almost the same and the cutting process became more stable. The cutting force also increased as the increase of cutting parameters, which was attributed to the strain-hardening effect. The roughness of machined surface decreased by ~ 39.7% with the increase of number of cutting edges from 3 to 12. The increase of feed rate per tooth could reduce the tensile residual stress on the machined surface. The burr on chip edges decreased, and the degree of chip deformation increased with the increase of the number of cutting edges. The tool failure mode was the adhesive wear of the rake face. With the increase of the number of cutting edges in the ultra-fine-pitched milling, the cutting efficiency and tool life could be significantly improved.