Process design and tool path generation for end milling considering tool life

Abstract

In mass production, the tool life of cutting tools is generally controlled by the number of parts to be machined and the machining time, making it difficult to operate each tool to its full life. In addition, it is desirable to avoid tool changes due to tool life during machining in order to avoid an increase in machining setup time. This study proposes a process design and tool path generation method that predicts tool life based on the tool flank wear width as a cumulative value of the contact length between the tool edge and workpiece during machining, and selects tool assignments and machining sequences for machined parts based on the predicted tool life. Based on the contact length corresponding to the defined tool life and the contact length estimated by machining simulation, a tool is selected that can use up as much of the tool life as possible. Since the contact length during machining varies depending on the cutting conditions, this study proposes a method to shorten the machining time by generating tool paths with different cutting conditions to accelerate the progression of tool flank wear and use up the tool to the limit of its service life, even in situations where the tool is conventionally discarded because it cannot be used up to the limit of its life.

Keywords

• tool life prediction
• end-milling
• tool wear
• tool change
• machining simulation
• contact length