Abstract
This paper presents the specifics of the two types of end-milling, up- and down-milling, in the context of process planning of a finishing operation for machining complex pocket features. An optimisation mechanism is used for a pocket type of end-milling operation with the aim of comparing the results from up- and down-milling. Two sets of cutting conditions have been generated and analysed for each type of end-milling-one with constant parameters for the entire tool path, derived from the worst case of cutting (representing the usual process planning approach) and another set representing the optimised process. The predicted results were verified through experiments. The optimized cutting parameters, when machining the critical corner, demonstrate the important changes in magnitude and direction of the radial cutting-tool deviation and surface error.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Stori, J. A., Wright, P. K., and King, C., “Integration of process simulation in machining parameter optimization,” ASME Journal of Manufacturing Science and Engineering, Vol. 121, No. 1, pp. 134–143, 1999.
Li, Z. Z., Zheng, M., Zheng, L., Wu, Z. J., and Liu, D. C., “A solid model-based milling process simulation and optimization system integrated with CAD/CAM,” Journal of Materials Processing Technology, Vol. 138, pp. 513–517, 2003.
Lee, S. and Lee, J., “Real-time inertia compensation for multi-axis CNC machine tools,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 9, pp. 1655–1659, 2012.
Landon, Y., Segonds, P., Lascoumes, P., and Lagarrigue, P., “Tool positioning error (TPE) characterisation in milling,” International Journal of Machine Tools and Manufacture, Vol. 44, pp. 457–464, 2004.
Hatna, A., Grieve, R. J., and Broomhead, P., “Automatic CNC milling of pockets: geometric and technological issues,” Computer Integrated Manufacturing Systems, Vol. 11, pp. 309–330, 1998.
Lee, S. K. and Ko, S. L., “Improvement of the accuracy in the machining of a deep shoulder cut by end milling.” Journal of Materials Processing Technology, Vol. 111, pp. 244–249, 2001.
Dotcheva, M. and Millward, H., “The application of tolerance analysis to the theoretical and experimental evaluation of a CNC corner-milling operation,” Journal of Materials Processing Technology, Vol. 170, pp. 284–297, 2005.
Gere, J. and Timoshenko, S., “Mechanics of Materials, 3rd edition,” Chapman and Hall, 1995.
Xu, A. P., Qu, Y. X., Zhang, D. W., and Huang, T., “Simulation and experimental investigation of the end milling process considering the cutter flexibility,” International Journal of Machine Tools and Manufacture, Vol. 43, pp. 283–292, 2003.
Childs, T. H. C., Maekawa, K., Obikawa, T., and Yamane, Y., “Metal Machining-Theory and Application,” London: Arnold, 2000.
Toh, C. K., “Surface topography analysis when high-speed rough milling hardened steel,” Materials and Manufacturing Processes, Vol. 18, No. 6, pp. 849–862, 2003.
Loftus, M. and Wang, D., “A theory to support the high-speed computer numerical control machining of corner profiles,” Proceedings of IMechE Part B: Journal of Engineering Manufacture, Vol. 216, pp. 643–647, 2002.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Dotcheva, M., Dotchev, K. & Popov, I. Modelling and optimisation of up-and down-milling processes for a representative pocket feature. Int. J. Precis. Eng. Manuf. 14, 703–708 (2013). https://doi.org/10.1007/s12541-013-0094-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-013-0094-y