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.

In the present study, the impact of cutting-edge microgeometry on the cutting forces in the finish milling of a 7075-aluminium alloy was analysed. The influence of selected values of the rounding radius of cutting edge, and the size of the margin width, on the cutting-force parameters was analysed. Experimental tests were carried out for different cross-sectional values of the cutting layer, changing the feed per tooth and radial infeed parameters. An analysis of the various statistical parameters of the force signal was performed. Experimental mathematical models of the relationship of the force parameters to the radius of the rounded cutting edge and the width of the margin were developed. The cutting forces were found to be most strongly influenced by the width of the margin and, to a minor extent, by the rounding radius of the cutting edge. It was proved that the effect of margin width is linear, and the effect of radius R is nonlinear and nonmonotonic. The minimum cutting force was shown to be for the radius of rounded cutting edge of about 15–20 micrometres. The proposed model is the basis for further work on innovative cutter geometries for aluminium-finishing milling.

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.