Analysis of cutting forces in end milling of multi- layered functionally graded metal material

Machining of functionally graded metal materials is an important operation in their integration into automotive tool making industry. Effective machining of these materials with changing properties requires detail knowledge of cutting forces which may result excessive product damage. Therefore, in this research, an experimental investigation was carried out to realize the machinability behavior of the fourlayered functionally graded metal material in terms of the nature of the cutting force generated while performing the machining operation. A dynamometer was used to measure the actual cutting forces, which were graphically represented by diagrams depending on the angle of rotation of the cutting tool. The machining of 16MnCr5/316L four-layered metal material, manufactured by the laser engineered net shaping (LENS) process, was performed with a solid carbide ball-end mill. The influence of LENS process parameters, machining parameters and hardness and /or thickness of the deposited layers on resultant maximum cutting forces has been investigated in the analyses. The results were graphically represented.