Pocket milling strategies using combined-mode and feed-direction-dependent stability criteria

Abstract

Abstract Pocket milling remains a key operation in the machining of aerospace structural components. This paper motivates a new combined-mode and feed-direction-dependent stability criteria to minimize pocket machining times, thereby improving productivity. Combined-mode milling models that include the influence of pre-existing slots in the workpiece to determine the optimal combination of engagements for up/down milling conditions are discussed in conjunction with feed-direction dependent stability models that exploit the role of dynamics projected in different feed directions to determine maximum machining stability limits. Model predictions supported by limited experimental validation demonstrate potential productivity gains of up to 60% using this new approach.