Journals Proceedings

Abstract

Ball-end milling is widely used as a surface finishing process. The selection of the proper cutting conditions, that is the spindle speed as well as the feed rate, is crucial for the optimization of the process. This selection is made according to the cutting speed, which is specified by the cutting tool and workpiece materials. In the case of ball-end milling of complex surfaces, the cutting speed varies depending on the changing effective diameter at the point of contact between the cutting tool and the workpiece. Therefore the cutting speed does not remain stable during the process, which directly influences the quality of the finished surface. One way to overcome this problem would be to continuously change the rotational speed of the cutting tool according to the variable effective diameter so as to keep the cutting speed constant, yet this solution is not technically feasible. In the present study, an experimental method for the specification of the optimum cutting conditions based on the control of the surface quality that several ball-end milling strategies offer, is presented. The selection of the above mentioned cutting conditions is made in accordance with the desired predefined quality of the machined surface as specified by its roughness.