Barrel tools are increasingly used in high-precision machining of free-form surfaces. However, limited studies evaluate their performance specifically on spherical geometries, where tool–surface contact characteristics differ significantly. Understanding how tool geometry and process parameters influence surface quality and cutting forces in such cases remains underexplored. This study evaluates how barrel cutter radius and varying machining parameters affect cutting forces and surface roughness when milling internal and external spherical surfaces. Machining tests were conducted on structural steel 1.1191 using two barrel cutters with different curvature radii (85 mm and 250 mm) on a 5-axis CNC machine. Feed per tooth and radial depth of cut were systematically varied. Cutting forces were measured using a dynamometer, and surface roughness was assessed using the Rz parameter, which is more sensitive to peak deviations than Ra. Novelty lies in isolating spherical surface shapes (internal vs. external) under identical path trajectories and systematically correlating tool geometry to force and surface metrics. The larger curvature tool (250 mm) consistently generated up to twice the cutting force of the smaller radius tool under equivalent conditions. External surfaces showed higher Rz values than internal ones due to less favorable contact geometry. Radial depth of the cut had a linear influence on force magnitude, while feed rate had a limited effect except at higher depths. Smaller-radius barrel tools and internal geometries are preferable for minimizing cutting forces and achieving better surface quality when machining spherical components. The aim of this paper is to determine the actual force load and surface quality when using specific cutting conditions for internal and external spherical machined surfaces.

This article examines the effect of the number of inserts in a milling head on cutting forces during machining and the resulting surface roughness. An experimental study was used to compare results using different insert configurations while maintaining a constant feed per tooth. The resulting cutting forces and surface roughness were analyzed and discussed in the context of the optimal setting of cutting conditions. It was found that a reduced number of inserts does not necessarily lead to a reduction in cutting forces during machining and that while maintaining the feed per tooth with a reduced number of inserts, the roughness is not significantly affected. An unexpected result was that inserts can differ in terms of the surface quality achieved. This research also shows that individual inserts can vary substantially in the force load they generate, a phenomenon that can be attributed to their dimensional differences. This study provides valuable insights for industrial applications that require precision machining concerning cutting forces and surface quality. It can potentially improve the efficiency and quality of machining in industrial applications.

This research paper is concerned with the experimental study of high-feed end milling of 1.4541 (X6CrNiTi18-10) stainless steel with replaceable cermet plates. Several machining operations were performed under different cutting conditions. The variable values were depth of cut, feed per tooth and cutting speed. The results were analyzed, and cutting forces were evaluated for dependence on cutting conditions (cutting speed, depth of cut, feed per tooth). The obtained data were statistically processed and plotted in graphs. It was found that the percentage distribution of cutting forces changed as the tool load increased. The ratio of forces acting in individual axes also changed with varying trends. An increasing trend was recorded in the x and y axes, while a decreasing trend was recorded in the z axis. Measured change, approximately 10%, can no longer be neglected as it can significantly influence the clamping stability of a part.

This paper deals with the issue of selecting different machining parameters in the CAM system Siemens NX 1946. The issue of choosing between a solid end mill, milling cutter, and a high-feed tool when machining simple rectangular and rugged cavities concerning time and residual material is solved here. The chosen material was 1.1730, which is a basic material for the production of moulds without heat treatment. The paper deals with the issue of choosing the size of tool feed into the cut and its influence on the formation of the machining path depending on the depth of the cavity. The size of the residual material depends on the machining strategy and the choice of the plunge method into the material with regard to the total machining time. Performed simulations and experiments have shown a significant impact in individual settings and, thus, on the cost of machining components of such shapes.

Barrel tools are relatively new tools that use atypical geometries to achieve shorter production times and improve surface quality. They have been increasingly used in the finishing operations industry, where they are gaining more and more popularity. For their optimal use, it is necessary to know how these tools behave during work in terms of how they load the machined product and what surface qualities they can achieve. For this reason, this study was conducted to compare two tools when machining a free surface. The obtained surface quality and the force load caused by the tool were evaluated. It was found that barrel tool machining results in a heterogeneous surface caused by different cutting speeds along the length of the tool and that the two obtained regions show differences in the obtained roughness. Even though the operation was classified as a finishing process, a difference of up to 30% was identified in the cutting forces acting on the tool and the workpiece.