Optimized CNC end-milling: A practical approach

This work proposes and implements a solution to achieve integrated product development that is seamlessly interfaced with optimized CNC end milling. The proposed solution is accurate and general and uses innovative techniques that are new to the field of metal-cutting modelling, simulation and optimization. In addition, the proposed solution is practical and its implementation can be easily and rapidly transferred to industry. First, the current work uses a novel and generic methodology for modelling the geometric aspect of the milling process. Second, techniques from artificial intelligence are introduced to model and optimize the milling process. Next, CAD/CAM and standard engineering development tools are adopted as the implementation tools and platform, and industry and CAD/CAM standards are used as the representations and standards in the development. Finally, the CAD/CAM platform is seamlessly interfaced with CNC production through the development of post-processors for typical CNC controllers found in industry. The system is demonstrated and verified for a typical industrial machining scenario, namely Pocket milling. The results demonstrate the system validity, applicability and accuracy.