Abstract
The milling process is crucial for enhancing the surface quality and accuracy of laser cladding layers in blade repair. However, the cutting force characteristics significantly differ due to the coarse profile of the laser cladding layer, leading to variable tool-workpiece engagement and dynamic responses during the machining process. In this research, we introduce a novel cutting force model formulated through a Fourier series expression, incorporating coefficients that account for vibrations caused by the uneven surface of the laser cladding. This advanced model aims to provide an analytical solution for force-induced vibrations and to quantify the impact of the coarse profile on these dynamics. To validate the efficacy of our proposed model, we conducted milling simulations and compared the results with those obtained from milling normal surfaces. Our findings indicate that the topography of laser cladding layers results in a lower peak cutting force and alters the natural frequencies of the system. This research not only validates the superiority of our model but also offers significant insights into optimizing the milling process for laser cladding blade repair, promising enhanced performance and reliability.
