Geometrical analysis of thread milling – Part 2:Calculation of uncut chip thickness

Thread milling offers interesting possibilities for machining internal or external threads. This machining technique uses a mill with a triangular profile for metric threads and a helical interpolation strategy. Thus, the uncut chip thickness can not be easily evaluated from a simplified approach. The present study deals with a model for calculating uncut chip thickness during internal thread milling. This step is needed to understand and model the cutting forces. The model developed uses the geometrical definitions of the mill, and takes into account the milling mode and the cutting conditions. The link with the interferences between the tool and the thread is also established and corroborates a previous study. A full analyticalformulation of the problem is proposed, and results from different milling settings are presented

Constrained optimization strategies and CAM software for single-pass peripheral milling

Constrained optimization strategies and computer flow charts for single-pass rough peripheral milling on NC/CNC and conventional machine tools are presented and discussed. Various practical machine tool constraints have been considered, namely the maximum available power, torque and feed force, and feed speed and cutting speed limits. The optimization strategies for this common operation have been found to be very complex and require computer assistance. A comparison of handbook recommended and optimal solutions has highlighted the significant benefits of using the latter, and the need for minimizing the component loading time and cost to maximize such benefits

Optimization of cutting parameters in micro end milling operations in dry cutting condition using genetic algorithms

10.1007/s00170-005-0148-0International Journal of Advanced Manufacturing Technology3011-121030-1039IJAT

Computer-aided constrained optimization analyses and strategies for multipass helical tooth milling operations

The development of computer-aided constrained optimization analyses and strategies for multipass peripheral and end-milling operations are outlined and discussed. The constrained optimization is based on criteria typified by the maximum production rate and includes a range of practical constraints of relevance to rough milling such as the machine tool limiting power, torque, feed force and feed-speed boundaries. It is shown that a combination of mathematical optimization analyses and limited use of numerical search techniques provides clearly defined computer-aided strategies which guarantee the final global optimum solutions. Simulation studies have verified the software and demonstrated the superiority of multipass over single pas