Efficient CNC Milling by Adjusting Material Removal Rate
This paper describes a combined mathematicalgraphical
approach for optimum tool path planning in order to
improve machining efficiency. A methodology has been used that
stabilizes machining operations by adjusting material removal rate in
pocket milling operations while keeping cutting forces within limits.
This increases the life of cutting tool and reduces the risk of tool
breakage, machining vibration, and chatter. Case studies reveal the
fact that application of this approach could result in a slight increase
of machining time, however, a considerable reduction of tooling cost,
machining vibration, noise and chatter can be achieved in addition to
producing a better surface finish.
[1] L. Song, S. K. Cao, K. Feng Song, C. Z. Wu, and W. W. Song,
"Software Module Development for Free-Form Surface Five-Axis
Machining Path and Tool Posture Simultaneous Optimization", Applied
Mechanics and Materials, vol.55-57, 2011, pp.1932-1937.
[2] M. Tolouei-Rad, "An approach towards fully integration of CAD and
CAM technologies," Journal of Achievements in Materials and
Manufacturing Engineering, vol. 18, 2006, pp. 31-36.
[3] H. El-Mounayri, H. Kishawy, and V. Tandon, "Optimized CNC endmilling:
a practical approach," International Journal of Computer
Integrated Manufacturing, vol. 15, 2002, pp. 453-470.
[4] M. Chandrasekaran, M. Muralidhar, C. Murali Krishna and U. S. Dixit,
"Application of soft computing techniques in machining performance
prediction and optimization: a literature review," International Journal
of Advanced Manufacturing Technology, vol. 46, 2010, pp. 445-464.
[5] A. A. Afifi, D. R. Hayhurst, and W. A. Khan, " Non-productive tool path
optimization of multi-tool part programs," International Journal of
Advanced Manufacturing Technology, vol. 55, no. 9-12, 2011, pp. 1007-
1023.
[6] C. H. Chu, C. T. Lee, K. W. Tien and C.J. Ting, "Efficient tool path
planning for 5-axis flank milling of ruled surfaces using ant colony
system algorithms," International Journal of Production Research, vol.
49, 2011, pp. 1557-1574.
[7] Z. C. Wei, M. J. Wang, J. N. Zhu and L. Y. Gu, "Cutting force
prediction in ball end milling of sculptured surface with Z-level
contouring tool path," International Journal of Machine Tools and
Manufacture, vol. 51, 2011, pp. 428-432.
[8] J. K. Rai, D. Brand, M. Slama and P. Xirouchakis, "Optimal selection of
cutting parameters in multi-tool milling operations using a genetic
algorithm," International Journal of Production Research, vol. 49, no.
10, 2011, pp. 3045-3068.
[9] X. F. Zhao, X. L. Liu, D.K. Jia and K. Ding, "Ball-end milling force
modeling and simulation based on cutting path optimization
experiments," Advanced Materials Research, vol. 188, no. 9-12, 2011,
pp. 348-351.
[10] Choy, H. S. and Chan, K. W., "A corner-looping based tool path for
pocket milling," Computer-Aided Design, vol. 35, 2003, pp. 155-166.
[11] Z. Yao and S.K. Gupta, "Cutter path generation for 2.5D milling by
combining multiple different cutting path patterns," International
Journal of Production Research, vol. 41, 2004, pp. 2141-2161.
[12] H. C. Kim and M. Y. Yang, "An optimum 2.5D contour parallel tool
path," International Journal of Precision Engineering and
Manufacturing, vol. 8, 2007, pp. 16-20.
[13] H. S. Choy and K.W. Chan, "A corner-looping based tool path for
pocket milling," Computer-Aided Design, vol. 35, 2003, pp. 155-166.
[14] T. Kramer, Pocket milling with tool engagement detection, SME
Publication, Product ID: JS92WBD2, 1992.
[15] E. Budaka and A. Tekelia, "Selection of axial and radial depth of cut
pairs," CIRP Annals - Manufacturing Technology, vol. 54, 2005, pp.
353-356.
[16] M. Rauch and J. Y. Hascoet, "Rough pocket milling with trochoidal and
plunging strategies," International Journal of Machining and
Machinability of Materials, vol. 2, 2007, pp. 161-175.
[17] M. Tolouei-Rad and I. M. Bidhendi, "On the optimization of machining
parameters for milling operations," International Journal of Machine
Tools & Manufacture, vol. 37, 1997, pp. 1-16.
[18] S. H. Bae, K. Ko, B. H. Kim and B. K. Choi, "Automatic feedrate
adjustment for pocket machining," Computer-Aided Design, vol. 35,
2003, pp. 495-500.
[1] L. Song, S. K. Cao, K. Feng Song, C. Z. Wu, and W. W. Song,
"Software Module Development for Free-Form Surface Five-Axis
Machining Path and Tool Posture Simultaneous Optimization", Applied
Mechanics and Materials, vol.55-57, 2011, pp.1932-1937.
[2] M. Tolouei-Rad, "An approach towards fully integration of CAD and
CAM technologies," Journal of Achievements in Materials and
Manufacturing Engineering, vol. 18, 2006, pp. 31-36.
[3] H. El-Mounayri, H. Kishawy, and V. Tandon, "Optimized CNC endmilling:
a practical approach," International Journal of Computer
Integrated Manufacturing, vol. 15, 2002, pp. 453-470.
[4] M. Chandrasekaran, M. Muralidhar, C. Murali Krishna and U. S. Dixit,
"Application of soft computing techniques in machining performance
prediction and optimization: a literature review," International Journal
of Advanced Manufacturing Technology, vol. 46, 2010, pp. 445-464.
[5] A. A. Afifi, D. R. Hayhurst, and W. A. Khan, " Non-productive tool path
optimization of multi-tool part programs," International Journal of
Advanced Manufacturing Technology, vol. 55, no. 9-12, 2011, pp. 1007-
1023.
[6] C. H. Chu, C. T. Lee, K. W. Tien and C.J. Ting, "Efficient tool path
planning for 5-axis flank milling of ruled surfaces using ant colony
system algorithms," International Journal of Production Research, vol.
49, 2011, pp. 1557-1574.
[7] Z. C. Wei, M. J. Wang, J. N. Zhu and L. Y. Gu, "Cutting force
prediction in ball end milling of sculptured surface with Z-level
contouring tool path," International Journal of Machine Tools and
Manufacture, vol. 51, 2011, pp. 428-432.
[8] J. K. Rai, D. Brand, M. Slama and P. Xirouchakis, "Optimal selection of
cutting parameters in multi-tool milling operations using a genetic
algorithm," International Journal of Production Research, vol. 49, no.
10, 2011, pp. 3045-3068.
[9] X. F. Zhao, X. L. Liu, D.K. Jia and K. Ding, "Ball-end milling force
modeling and simulation based on cutting path optimization
experiments," Advanced Materials Research, vol. 188, no. 9-12, 2011,
pp. 348-351.
[10] Choy, H. S. and Chan, K. W., "A corner-looping based tool path for
pocket milling," Computer-Aided Design, vol. 35, 2003, pp. 155-166.
[11] Z. Yao and S.K. Gupta, "Cutter path generation for 2.5D milling by
combining multiple different cutting path patterns," International
Journal of Production Research, vol. 41, 2004, pp. 2141-2161.
[12] H. C. Kim and M. Y. Yang, "An optimum 2.5D contour parallel tool
path," International Journal of Precision Engineering and
Manufacturing, vol. 8, 2007, pp. 16-20.
[13] H. S. Choy and K.W. Chan, "A corner-looping based tool path for
pocket milling," Computer-Aided Design, vol. 35, 2003, pp. 155-166.
[14] T. Kramer, Pocket milling with tool engagement detection, SME
Publication, Product ID: JS92WBD2, 1992.
[15] E. Budaka and A. Tekelia, "Selection of axial and radial depth of cut
pairs," CIRP Annals - Manufacturing Technology, vol. 54, 2005, pp.
353-356.
[16] M. Rauch and J. Y. Hascoet, "Rough pocket milling with trochoidal and
plunging strategies," International Journal of Machining and
Machinability of Materials, vol. 2, 2007, pp. 161-175.
[17] M. Tolouei-Rad and I. M. Bidhendi, "On the optimization of machining
parameters for milling operations," International Journal of Machine
Tools & Manufacture, vol. 37, 1997, pp. 1-16.
[18] S. H. Bae, K. Ko, B. H. Kim and B. K. Choi, "Automatic feedrate
adjustment for pocket machining," Computer-Aided Design, vol. 35,
2003, pp. 495-500.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:61430", author = "Majid Tolouei-Rad", title = "Efficient CNC Milling by Adjusting Material Removal Rate", abstract = "This paper describes a combined mathematicalgraphical
approach for optimum tool path planning in order to
improve machining efficiency. A methodology has been used that
stabilizes machining operations by adjusting material removal rate in
pocket milling operations while keeping cutting forces within limits.
This increases the life of cutting tool and reduces the risk of tool
breakage, machining vibration, and chatter. Case studies reveal the
fact that application of this approach could result in a slight increase
of machining time, however, a considerable reduction of tooling cost,
machining vibration, noise and chatter can be achieved in addition to
producing a better surface finish.", keywords = "CNC machines, milling, optimization, removal rate.", volume = "5", number = "10", pages = "2047-5", }
