Simulation-based cutting parameter selection for ball end milling

This paper on ball end milling presents strategies and algorithms for selecting cutting parameters such as width of cut (WOC), feed rate, and spindle speed. One of the major goals is to minimize the overall machining time, but within the constraints of (1) the cutting tool limitations (such as the CNC machine tool capability and the tool strength) and (2) the design specifications of the part being machined (such as the allowable surface finish, the accuracy of machined dimensions of prismatic pockets, and the faithfulness between the CAD-specified free-form contours and the as-machined free-form contours-usually referred to as allowable form error). This is a multiple-variable and multiple-constraint optimization problem. To solve it, first a process model for ball end milling is developed. Based on this model, the form error can be predicted from cutting parameters with simulation software. Second, the cutting parameter space is explored and analyzed, and some important properties that simplify the searching process are discovered. Based on the simulation software and the properties of the cutting parameter space, a simulation-based cutting parameter selection process is developed that does minimize machining time within given constraints.