Factorial study on nonlinear characteristics of ultra high strength alloy steel in high-speed cutting process

Factorials design and uniform design are applied in the high-speed end-milling experiments of ultra high strength steel (hardness > 50 HRc, tensile strengthob> 1.4 GPa). The characteristics of this difficult-to-cut material in high-speed cutting process are analyzed and a nonlinear mathematics model on the relationship between cutting force and cutting regimes is proposed. Experiments indicate that under the high-speed cutting of ultra high strength alloy steel condition, the interaction between depth of cut and feed per tooth, the interaction between width of cut and depth of cut, and the interaction between width of cut and feed per tooth are among the statistic significant effects on cutting force; the relationships between cutting forces and cutting regimes are nonlinear, the scale effect of cutting parameters is significant; the effect of one cutting parameter on cutting force is sensitive to the choice of other cutting parameters.