Cutting Forces and Surface and Flake Quality from Face-Milling Combinations

Yellow-poplar, sugar maple, and red oak at 8 percent moisture content were face milled at three downmilling feed positions and three depths of cut (0.005, 0.010, and 0.020 in.) and up to a 10-inch cutting circle. One knife was mounted on the experimental face mill and turned at 25 rpm. The face-milled surfaces were 7/8 inch by 12 inches and fed at 30 inches per minute. The oblique rake angle was varied from 60? to 30? at increments of 7-1/2?. The radial rake angle was varied negatively and positively at increments of 5? until the surface and bottom edge quality deteriorated or until the knife skipped at a given feed rate. Three mutually perpendicular workpiece force components were recorded and measured parallel and perpendicular to the feed direction. Surface quality was measured from profiles that were traced with a stylus. Satisfactory surfaces and flake shapes for particleboard were produced at many conditions. Tear-out depth was less than 0.012 inch at selected milling conditions such as 0.010-inch depth of cut, 4.80-inch feed position below the cutterhead axis, 52? oblique rake angle, and -40? radial rake angle.

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