Methodology for optimizing cutting parameters on milling process

Abstract

Obtaining a better surface roughness with less time and energy consumption is an essential consideration in machining today. Choosing the right strategy for finishing milling is a difficult task to achieve when milling complex surfaces. It is essential to improve production rate and cutting quality. This paper presents a way to optimize the milling process based on the tool path trajectory type for inclined or complex surfaces machined with a ball end mill. In this case the speeds and feeds differ because the depth of cut changes according with the effective diameter for a ball nose mill. The research is based on several steps: the cutting regime is calculated with the classic formulas, then the part is machined and the quality of the resulting part is analysed by roughness measurement; a correction coefficient is calculated and the feederate is adjusted. The procedure is resumed and the tool setup is done, the part is machined and time, roughness and length of the trajectory are measured in order to validate the correction coefficient.