Evaluation of Hard Milling and Wire Electro-Discharge Machining on Hardened D2 Steel - Process Economics and Workpiece Surface Integrity

摘要

This study presents general guidelines to establish realistic machining center specifications, in terms of maximum spindle speeds and feed rates, for milling of sculptured surfaces. These machine specifications are based on different combinations of cutting tool shapes, cutting tool sizes and work-piece materials. During high-speed milling of sculptured surfaces, the controller needs to maintain a small following error by overriding the programmed feed rate during sharp changes in tool-path direction. This controller behavior can lead to significant discrepancies between ideal cycle time (total path length/programmed feed rate) and actual cycle time.