A STUDY OF INCREASE TOOL LIFE OF MILLING MACHINE USING DYNAMIC MILLING

MECHANICAL ENGINEERING

Milling is a commonly used machining process where a rotating cutter removes material from the workpiece. In recent years, attention has been turned towards so called dynamic milling methods which differ from the conventional way of milling. Dynamic milling normally uses, as opposed to the conventional way, more of the axial cutting edge, smaller radial depth of cut, significantly higher cutting speed and feed per tooth. The method has demonstrated potential to save both time and money under specific circumstances, for manufacturing companies. The results of this study show that dynamic milling parameters can give several benefits regarding tool life and material removal rate and minimize machining cost. When machining in Hardox 600 end mills able to achieve a higher material removal rate and cutting tool lifetime with dynamic parameters compared to more conventional ones Results from the analysis showed that the dynamic parameters generated a smoother surface while the surface results from Hardox were more equivocal. Dynamic milling is a method that often uses the full length of the tool combined with a small radial depth, higher cutting speed and feed per tooth. This can potentially increase the material removal rate significantly compared to traditional methods. Dynamic milling techniques also use a toolpath programmed to achieve the most efficient cut. This is often done by keeping the tools angle of engagement constant through the operation in order to keep a consistent load. The main conclusion was that milling with dynamic parameters is generally more advantageous and should be utilised, if possible.

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