OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 zone and affects the overall force interaction pattern. Understanding the relationship between the tool’s geometrical parameters (ω and B), the process kinematics (cutter rotation), and the cutting force dynamics (Pz, Py, Ph, Pv) is necessary for optimizing the milling process and achieving the best possible surface finish (see Fig. 5). More accurate process modeling requires considering all these factors, as well as the influence of tool geometry, workpiece material properties, and cutting parameters. Conclusion The study of milling workpieces made of Inconel 625 superalloy, produced by wire arc additive manufacturing (WAAM), revealed a number of key dependencies and patterns that are of practical importance for optimizing the technological process. The microstructure of Inconel 625 specimens formed by WAAM significantly affects the cutting forces. Microstructural analysis revealed a non-homogeneous distribution of hardness and grain size, caused by nonuniforn heating and cooling during layer-by-layer deposition. A correlation was established between local variations in microhardness and cutting forces; increased hardness in the surface layers and specific areas of the sample led to an increase in cutting forces and more intensive tool wear compared to conventionally manufactured parts. This emphasizes the need to adapt cutting modes to the specific microstructural characteristics of workpieces produced by WAAM method. Optimal cutting modes, ensuring minimization of cutting forces and tool wear, significantly depend on the specific machining parameters. For milling Inconel 625 workpieces produced by WAAM technology, it is optimal to use high-strength carbide milling cutters with increased wear resistance. The application of mills with wear-resistant coatings (e.g., TiAlN, AlCrN) is possible to increase tool life. It is best to use special geometry mill cutters of a larger diameter than when machining 0.40 C-13Cr steel. Increasing the mill cutter diameter by more than 8 mm leads to an increase in the mill cutter price proportionally to the square of the mill cutter diameter. For rough machining, consider using milling cutters with an increased helix angle to achieve a smoother entry and exit from the material and reduce vibrations. Milling is recommended to begin with low cutting speeds (e.g., at V = 15.8 m/min). Subsequently, the speed can be gradually increased, while controlling the cutting edge temperature and tool wear. Excessive feed rates (80 mm/min or more when feeding along the workpiece), should be avoided, especially when milling perpendicular to the deposition direction, to prevent excessive cutting forces and tool wear. The use of conventional milling when machining Inconel 625 alloy is categorically unacceptable, as it leads to table jerking and end mill breakage, which is especially evident at feed rates exceeding 40 mm/min. Excessive cutting speeds (above 50 m/min) when milling Inconel 625 alloy causes the machined material to adhere to the cutter tooth due to the increased temperature in the cutting zone, which, in turn, can lead to a sharp increase in cutting forces and tool breakage. Increasing the number of teeth while maintaining the same cutter diameter leads to chip welding to the chip helical groove and a sharp increase in temperature in the cutting zone. This is due to friction between the compressed chip material in the chip helical groove and the cutting surface, ultimately causing the cutter to failure. The use of specialized tooling is a prerequisite for effective machining. The increased abrasiveness and heterogeneity of Inconel 625 workpieces produced by WAAM require the use of high-strength carbide milling cutters with enhanced wear resistance and, potentially, a specialized geometry. The empirical relationships developed in this study, along with recommendations for tool selection and cutting parameter optimization for milling Inconel 625 workpieces produced by WAAM, will improve the efficiency and productivity of machining additively manufactured parts. However, further research is needed for a deeper understanding of the influence of residual stresses and the development of methods for their control. This will enable the optimization of milling processes to achieve high levels of surface quality, productivity, and economic efficiency.
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