Integrated strategies for high performance peripheral milling
High performance peripheral milling is one of the most common rough machining operations in modern production environments. Productivity of these operations, characterized by material removal rates (MRR) and machining times, is a function of several parameters: spindle speed, feed, axial and radial depths of cuts, tool path type, milling mode, and feed direction. Each of these variables affects the MRRs differently; the limiting case often resulting from the dynamic interactions between the cutting tool and the work piece - characterized by chatter vibrations. This paper proposes an integrated approach incorporating all of the significant factors affecting performance to formulate a mixed mode milling strategy for the case of profile-parallel peripheral milling of a rectangular part. Numerical investigations demonstrate an improvement in machining time of up to 28% over conventional approaches. Proposed methods can be used for selection of optimal cutting conditions, tool path type, and for dynamically modifying the tool path to maximize MRRs and minimize the machining times.