The effect of the spindle speed control when milling free-form surfaces

Abstract

AbstractMachining free-form surfaces using ball-end mill is still common, especially for finishing and semi-finishing. However, due to the change in the surface inclination, the working diameter changes from one point to another, which affects the cutting parameters, especially the cutting speed. That means, even with constant spindle speed, the cutting speed varies during the milling process and affects the surface quality. This article defines a new method to keep the cutting speed constant, by calculating the working diameter at each point and changing the spindle speed accordingly. The results of using this method are illustrated, and a comparison was made between the surfaces of five workpieces under different feed directions before and after the optimization. The results emphasize the importance of maintaining a constant cutting speed to obtain a more homogeneous surface.