Minimum cutting thickness prediction model for micro-milling machining and experimental Study of FeCoNiCrMn high-entropy alloy machining

FeCoNiCrMn high entropy alloy has excellent properties such as high hardness, high strength and high wear resistance, which has a broad application prospect in aerospace, military and other fields. As an emerging difficult-to-machine material, the minimum cutting thickness determines the highest machining accuracy of micro-milling. In order to improve the micro-milling quality of FeCoNiCrMn high-entropy alloy, a minimum cutting thickness prediction model based on the effective front angle of the tool is established according to the analysis of micro-milling force model. Through the FeCoNiCrMn high-entropy alloy micro-milling processing experiments, the milling force parameters are calculated by substituting them into the prediction model, and the minimum cutting thickness value of FeCoNiCrMn high-entropy alloy is 1.367 μm when the flank radius of the milling cutter is 5 μm.When the feed rate of each tooth is in the range of 1 μm–1.5 μm, the severe size effect and the ploughing effect lead to the specific cutting energy nonlinearly increase, and the cutting force and surface roughness increase sharply with large fluctuations. From this, the range of the minimum cutting thickness of the high-entropy alloy was judged to be between 1 μm and 1.5 μm, and the accuracy of this prediction model was verified.