Feedrate optimization based on load control for corner-milling

Abstract

An approach of feedrate optimization is presented for corner-milling process through controlling the load. According to the actual trajectory model of cutting edge of ball-end mill, the mathematical model of the instantaneous chip thickness for corner-milling is proposed, which increases the forecasting accuracy. The milling force model is modified to meet the characteristic of corner-milling, which can be divided into five stages. The allowable load under the cutter deformation limitation is used for optimizing the feedrate by the dichotomy. To meet the machining requirements, second optimization for the optimized feedrate value is carried out in consideration of the restrictions on dynamics of the machine tools. By simulation computation, the variation of the load maintains stably with the optimized feedrate, and machining time decreases slightly. An experiment for corner-milling with ball-end mill is operated. Both the results of the milling force by simulation and measurement are well matched in magnitude and variation tendency. The method provides theoretic support for high efficiency and high precision processing in pocket machining.