A continuous oscillating milling strategy based on uniform wear theory for improving the service life of the ball-end cutter

Abstract

The rapid deterioration of ball-end cutters leads to a shortened lifespan when milling difficult-to-cut materials. This research introduced a continuous oscillating milling approach aimed at enhancing the consistency of cutting-edge wear by dynamically adjusting the tool axis oscillation angle, thus prolonging the tool life. Initially, key processing parameters were determined according to the actual processing conditions. Subsequently, a tool wear model, rooted in continuous oscillating milling, was developed. Using it, an optimization framework for the tool oscillating angle, based on uniform wear theory, was established. Then, the CNC code was compiled according to optimization results. Finally, the proposed milling strategy was demonstrated by cutting tests on Ni-based superalloy GH4169. The results demonstrated that this approach notably extended the tool life.