A New Strategy for End Milling Optimization

(*) Corresponding author

Authors' affiliations

DOI's assignment:
the author of the article can submit here a request for assignment of a DOI number to this resource!
Cost of the service: euros 10,00 (for a DOI)


Most of the currently available optimization strategies for machining operations are based on economic parameters such as production cost and machining time. In most cases, however, size tolerance is the first criterion for accepting the manufactured parts. As a result, these strategies might not be applicable in practice, despite their economic advantages. This paper proposes a new optimization strategy for a single-pass peripheral end milling process based on both technical and economic parameters, namely, specified parts tolerances and economical cutting speeds. First, the cutting speed is selected based on an economic parameter, such as the minimum cost per part or the maximum production rate. Then the circular direction search optimization strategy is employed to determine the best combination of feed rate and radial depth of cut to satisfy the specified part tolerance. The results indicate that the proposed strategy can be implemented successfully for process optimization. By being based on both technical and economic parameters, it provides a rational solution to the peripheral end milling optimization problem.
Copyright © 2014 Praise Worthy Prize - All rights reserved.


End Milling; Process Optimization; Size Tolerance; Circular Direction Search

Full Text:



F. W. Taylor, On the Art of Cutting Metals, Trans. ASME, Vol. 28, pp. 31-35, 1907.

C. A. Van Luttervelt, T. H. C. Childs, I. S. Jawahir, F. Klocke, P. K. Venuvinod, Present Situation and Future Trends in Modeling of Machining Operations, Annals of the CIRP, Vol. 47, n. 2, pp. 587-626, 1998.

I. S. Jawahir, X. Wang, Development of Hybrid Predictive Models and Optimization Techniques for Machining Operations. J. Mat. Proc. Tech., Vol. 185, pp. 46-59, 2007.

J. Wang, Computer-Aided Economic Optimization of End-Milling Operations, Int. J. Prod. Econ., Vol. 54, pp. 307-320, 1998.

M. C. Cakir, A. Gurarda, Optimization of Machining Conditions for Multi-Tool Milling Operations, Int. J. Prod. Res., Vol. 38, n. 15, pp.3537-3552, 2000.

N. Baskar, P. Asokan, R. Saravann , G. Prabhaharn, Optimization of Machining Parameters for Milling Operation Using Non-Conventional Methods, Int. J. Adv. Manuf. Technol., Vol. 25, pp.1078-1088, 2005.

S. M. Wu, D. S. Erner, Maximum Profit as the Criterion in Determination of the Optimum Cutting Conditions, ASME J. Eng. Ind., Vol. 88, pp. 435-442, 1996.

E. Budak, A. Tekeli, Maximizing Chatter Free Material Removal Rate In Milling Through Optimal Selection of Axial and Radial Depth of Cut Pairs, Annals of the CIRP, Vol. 54, n. 1, pp. 353-356, 2005.

K. K. Wang, Solid Modelling for Optimizing Metal Removal of Three-Dimensional NC End Milling, J. Manuf. Sys., pp.57-65, 1988.

S. D. Merdol, Y. Altintas, Virtual Cutting and Optimization of Three-Axis Milling Processes, Int. J. Mach. Tools & Manuf., Vol. 48, pp.1063-1071, 2008.

H. Oktem, An Integrated Study of Surface Roughness for Modelling and Optimization of Cutting Parameters During End Milling Operation, Int. J. Adv. Manuf. Technol. Vol. 43, pp.852-861, 2009.

B. Ozcelik, H. Oktem, H. Kurtaran, Optimum Surface Roughness in End Milling Inconel 718 by Coupling Neural Network Model and Genetic Algorithm. Int. J. Adv. Manuf. Technol. Vol. 27, pp. 234-241, 2005.

M. N. Islam, H-U. Lee, Cho D-W, Prediction and Analysis of Size Tolerances Achievable in Peripheral End Milling. Int. J. Adv. Manuf. Technol., Vol. 39, pp.129-141, 2008.

J. H. Ko, W. S. Yun, D-W. Cho, K. F. Ehmann KF, Development of a Virtual Machining System, Part 1: Approximation of The Size Effect for Cutting Force Prediction, Int. J. Mach. Tools & Manuf., Vol. 42, pp.1595-1605, 2002.

W. Yun, J. H. Ko, D-W. Cho, K. F. Ehmann, Development of a Virtual Machining System, Part 2: Prediction and Analysis of Machined Surface Error. Int. J. Mach. Tools & Manuf., Vol. 42, pp. 1607-1615, 2002.

W. S. Yun, J. H. Ko, H. U. Lee, D-W. Cho, K. F. Ehmann, Development of a Virtual Machining System, Part 3: Cutting Process Simulation in Transient Cuts. Int. J. Mach. Tools & Manuf., Vol. 42, pp. 1617-1627, 2002.

M. N. Islam, A CMM-based geometric accuracy study of CNC end milling operations, Proc. 6th Int. Conf. on Manuf. Engg. Melbourne, 1995, pp. 835-842.

E. Budak, Y. Altintas, Peripheral Milling Conditions for Improved Dimensional Accuracy, Int. J. Mach. Tools & Manuf., Vol. 34, pp. 907-918, 1994.

T. S. Ong, B. K. Hind, The Application of Tool Deflection Knowledge in Process Planning to Meet Geometric Tolerances. Int. J. Mach. Tools & Manuf., Vol. 43, pp.731-737, 2003.

T. J. Drozda, C. Wick C, Tool and Manufacturing Engineers’ Handbook: Machining (4th edition, SME, 1983).


  • There are currently no refbacks.

Please send any question about this web site to info@praiseworthyprize.com
Copyright © 2005-2023 Praise Worthy Prize