Optimizing machining parameters for milling pockets in waffle-grid shell structures

The paper aims to develop a procedure for calculating parameters characterizing the process of milling box-shaped parts with waffle-grid shell design made of high-strength aluminum alloys. The calculated parameters are approximated by power equations and are provided for various ranges of the technological coefficient for the bottom of the waffle-grid structure. During final machining and penetration, when setting up the advance, one should take into account the inertial properties of the linear drives of the machines, in addition to this the advance of the tool and the angle of penetration should be constrained to prevent deformation of the bottom of the pocket. Based on the results of the math simulations, the ranges of acceptable values for advance per a tooth and the penetration angle were defined. The optimal ranges for milling parameters were established, which are recommended for implementation in the manufacturing processes of machining box-shaped parts with waffle-grid shell design made of high-strength aluminum alloys.