Large overhang milling cutters face challenges, including poor cutting stability and surface quality when machining deep-cavity parts in aerospace and other industries. The combined interactions between overhang and process parameters significantly influence machining performance and the tool wear mechanism. In this study, the coupled effects of tool overhang length and feed per tooth on milling force, surface topography, chip morphology, and tool wear mechanism were systematically investigated under typical large overhang conditions. The tool stiffness decreased with increasing overhangs; the feed force decreased by approximately 32.4%~49.48%; and the chip morphology changed from continuous bands to fractures. The feed force increased by approximately 25.11%~67.34% with increasing the feed per tooth, resulting in reduced surface quality and accelerated tool wear. The novelty of this work lies in quantitatively revealing the coupling mechanism between overhang length and feed rate in large overhang milling, providing a theoretical basis for process optimization. The findings are directly applicable to the optimization of machining parameters for deep-cavity components such as aero-engine casings and optical mold cavities, where tool overhang is a critical factor affecting productivity and surface integrity. This study provides a theoretical foundation and experimental reference for optimizing process parameters when milling titanium alloy with long-overhang milling cutters.
Jiang et al. (Tue,) studied this question.
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