Abstract
This work presents new two-phase optimisation strategy for efficient planning of finishing end-milling operations when machining pocket-type features. The novel optimisation approach incorporates the design tolerance into an error stack that relates directly to the CAD/CAM output. The optimisation mechanism controls dimensional tolerances through knowledge of cutting forces and the associated cutting tool deflections. The new off-line optimisation methodology creates a more efficient milling process with variable feed rate than conventional constant feed rate.
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