High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut a_p and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

An experimental study of the abrasive water jet cutting process of Inconel 718 alloy samples with varying values of cutting speed, abrasive flow rate and cutting material height was carried out. Surface roughness and waviness were measured at different cutting depths, and the variation of the kerf angle was studied. It was shown that the depth of cut has the greatest effect on roughness and waviness. The height of the sample has no impact on the roughness and waviness at a particular depth of cut. As the depth of cut increases, in most cases, roughness and waviness increase as well. It has been proven that the cutting speed has a negligible effect on surface roughness, but it has a significant effect on surface waviness. The waviness, on the other hand, depends only slightly on the abrasive flow. It has been proven that the kerf angle does not depend on the abrasive flow. The kerf angle depends mainly on the height of the sample. The models were developed for the parameters of roughness Ra and Rz, waviness Wa and Wz and kerf angle. All models were calculated without separating the surface into smooth and rough cutting regions.

When face milling using a toroidal cutter, with a change in the depth of the cut, the entering angle varies as well. An experimental test of the influence of cutting parameters, such as the depth of the cut and the feed per tooth on the cutting force components and surface roughness parameters, was conducted. The experimental test was carried out using a DMU 100 monoBLOCK CNC machine with registration of cutting force components and surface roughness parameters Ra, Rz, and RSm. FEM analysis of the face-milling process was also carried out and compared with the experimental results. The average deviation of the FEM values for cutting force components does not exceed 12%. Experimental models were established for each force component. It was shown that the depth of the cut has the strongest influence on each force component. The feed per tooth has a little impact on the cutting force. The obtained model of the feed force component is the most complex, and the model of the F_a component is only linear. The influence of the a_p parameter on the surface roughness parameters is nonlinear and nonmonotonic. In the range of approx. a_p = 2 mm, there is a maximum surface roughness.

Inconel 718 alloy is characterised by high strength and corrosion resistance and remains stable at high temperatures, so it is widely used in the energy and aerospace industries. However, machining this material is difficult due to its high strength, hardness, and high specific force coefficient exceeding 3000 MPa. Turning of the Inconel 718 alloy can be carried out with negative and positive inserts. Therefore, the impacts of the insert geometry on the turning process of Inconel 718, cutting force components, and surface roughness were studied. Three positive and three negative insert geometries were tested. It was shown that the key influence on the active components of the cutting force is the effective rake angle. The surface roughness, on the other hand, depends mainly on the cutting-edge radius. It has been shown that the negative insert geometry with γ = 6° and r_n=22 μm provides a 30% lower cutting force than the positive inserts and the same surface roughness. The developed models of the cutting force components proved that when cutting with positive inserts, a higher specific cutting force occurs for the Inconel 718 alloy than for the negative insert. It was shown that technological parameters had a very similar effect on the cutting force components and surface roughness parameters regardless of the blade geometry. It was proven that the use of positive inserts makes sense only for depths of cut no greater than the size of the corner radius.

This study investigates the influence of cutting edge geometry (continuous, serrated, and wavy) and selected machining parameters (cutting speed v_c, feed per tooth f_z, and radial infeed a_e) on cutting-force components and dynamic behavior during the milling of an AlZn5.5MgCu aluminum alloy. The analysis was based on box plots and Recurrence Quantification Analysis (RQA) applied to the cutting-force signal. The results demonstrated that serrated and wavy-edge tools generated significantly lower values of the normal force component F_fN—up to −57% on average—compared to the continuous-edge tool, particularly at lower f_z and v_c, indicating enhanced process dynamics. At higher a_e values, however, these tools induced increased signal variability—up to 300% greater—suggesting potential resonance excitation. RQA indicators, such as DET, Lmax, and LAM, revealed a strong dependence of system dynamics on tool edge geometry. Linear Discriminant Analysis (LDA) confirmed that RQA measures effectively distinguish between cutting-edge types. The study concludes that tooldge geometry substantially affects milling process stability and can be purposefully selected to optimize performance under varying machining conditions.