Determination of optimum cutter diameter for machining 21/2-O pockets

Tool paths in milling are calculated using user-defined values of the radia l width of cut (b) and the cutter diameter (D), When calculating the other cutting parameters, most researchers and practising engineers assume that t he ratio of the radial width of cut to the cutter diameter i.e. b/D remains constant over the entire tool path length. However, in practice, when mach ining pockets and many other features with window-frame type toolpaths, b/D does not remain constant. In this paper, the optimum cutter diameter is ch osen following a consideration of the variation of b/D throughout the cutte r path. It is shown that while a smaller cutter diameter gives a more favou rable variation, it leads to a longer toolpath. Hence the final optimum cut ter diameter is a compromise between the increased costs of a larger diamet er with a shorter toolpath and the lower costs of a smaller diameter with a longer toolpath, (C) 2001 Elsevier Science Ltd. All rights reserved.