The Influence of Tool Path Strategies on Cutting Force and Surface Texture during Ball End Milling of Low Curvature Convex Surfaces

Abstract

Advancement in machining technology of curved surfaces for various engineering applications is increasing. Various methodologies and computer tools have been developed by the manufacturers to improve efficiency of freeform surface machining. Selection of the right sets of cutter path strategies and appropriate cutting conditions is extremely important in ensuring high productivity rate, meeting the better quality level, and lower cutting forces. In this paper, cutting force as a new decision criterion for the best selection of tool paths on convex surfaces is presented. Therefore, this work aims at studying and analyzing different finishing strategies to assess their influence on surface texture, cutting forces, and machining time. Design and analysis of experiments are performed by means of Taguchi technique and analysis of variance. In addition, the significant parameters affecting the cutting force in each strategy are introduced. Machining strategies employed include raster, 3D-offset, radial, and spiral. The cutting parameters were feed rate, cutting speed, and step over. The experiments were carried out on low curvature convex surfaces of stainless steel 1.4903. The conclusion is that radial strategy provokes the best surface texture and the lowest cutting forces and spiral strategy signifies the worst surface texture and the highest cutting forces.