| For mass production of uniform quality in modern industry, computer numeric control (CNC) machining is widely used. Generally, machining parameters in CNC machining are chosen from machining tables, skilled experience of empirical methods. One evident phenomena in machining is that tool wear is unavoidable; hence, the best management of cutting tools in mass production is the minimization of tool wear during sequential machining processes. No systematic selection of cutting parameters in CNC machining can guarantee proper cutting state in complex milling. To provide cutting information in a wide cutting range, a mechanistic cutting dynamic model is essential for a strong foundation in advanced machining industry.;Modern CAD/CAM systems are intended to support seamless manufacturing from conceptual design to machining. Benefits of CAD/CAM programs are automation of this sequence and reduction of machining programming time. Normally, conventional CAM systems use the cutting parameters converted values from the machining tables without consideration of diverse cutting conditions. Table driven selection of cutting parameters in conventional CAD/CAM can cause an overload on the cutting tool and result in inefficient machine and tool management. Adaptation of a mechanistic cutting dynamic model of the tool in a conventional CAD/CAM system is in high demand for complex cutting conditions involving different materials, tools and cutting parameters. This feature can minimize the tool wear and breakage that results from incorrect selection of cutting parameters.;In this dissertation, as a proper tool for a systematic framework for selection of cutting parameters in complex milling operations, a mechanistic cutting model for a wide range of cutting situations is developed. To verify this cutting dynamic model, a sequence of experiments are performed. When this advanced feature is added to conventional CAD/CAM systems, seamless machining with safe and efficient cutting parameters is possible. Based on a model developed in this thesis, a framework for selecting safe and efficient cutting parameters in various cutting situations is provided. Solid model based tool trajectory planning with consideration of the effect of the change of depth of cut is demonstrated. Finally, the efficiency of the unit machining process composed of tool trajectory and recommended cutting parameters will be shown for elimination of redundant calculations for the same milling cutting conditions. |
