Abstract
This study proposes a new efficient method to reduce maximum cutting torque loaded on ball end mill with continuous multi axis controlled machining. In the proposed method, tool posture in each cutter location defined by NC program is changed gradually byreferring estimated results of instantaneous cutting force and shape information of engagement domain removed cutting edges. In the planning process, the tool posture on each cutter location is replaced by a new candidate of tool posture, which can satisfy following conditions, 1. Ball end mill can remove work piece surface with smaller cutting force, 2. The removed part of work piece with the new tool posture candidate is equal to removed part with the original tool posture, 3. Side part of cutting tool does not interference machined workpiece surface. And, this gradual replace is repeated several times. These process are applied for each cutter location in continuous tool path in NC program. To shorten calculation time, the ultra-parallel processing technology is introduced In the developed prototype system, the engagement domain and side part of cutting tool is divided into a large number of estimation point.Then, inclusion estimation process between the estimation point and the machined work piece volume is decomposed into simple estimation processes about tool swept volume.
