Increasing chatter free material removal rate in die and mold machining

Higher material removal rates are necessary for shortening the die manufacturing period. There are several limitations for reduced productivity in die and mold machining. Chatter vibrations which develop due to dynamic interactions between the cutting tool and the workpiece, result in both reduced productivity and surface quality. Various numerical and analytical stability models have been considered in the previous publications for increasing chatter free material removal rate. In this paper, an analytical method is proposed to determine the optimal combination of axial and radial depths of cut in milling, so that chatter free material removal rate is maximized when roughing, or finishing a part. Since pocketing is a very common operation in die and mold milling, the application of the method is demonstrated on a pocketing example where significant reduction in the machining time is obtained using the optimal parameters. The procedure can easily be integrated to a CAD/CAM or virtual machining environment in order to identify the optimal milling conditions automatically.

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