Developing Energy Efficient Milling Strategy for Variable Curved Geometry Using Constant Engagement Method

Abstract

The continuous fluctuation in force profile in milling of variable curved geometry creates a barrier in stable machining and in cutting power consumption. The fluctuation in force profile happens due to alteration in chip load in the presence of workpiece curvature. The present study aims to develop an energy efficient machining strategy for milling of variable curved geometries where more uniform cutting force and cutting power consumption profiles are accomplished due to constant chip load along the peripheral length of curved geometry. The proposed strategy involves mechanics of milling, instantaneous cutting force and cutting power consumption. It is formulated based on constant chip load by regulating entry angle of milling cutter according to workpiece curvature along the peripheral length. Thus, the cutting power fluctuation that is occurred due to variation of workpiece curvature is reduced by regulating tool-workpiece engagement. The energy consumption is reduced almost 18 % using the proposed approach. It results into developing an energy efficient machining strategy for milling of variable curved geometry. It also provides stable machining process and increased tool life by reducing tool wear due to reduction of force fluctuation during metal removal process.