Effects of Machining Parameters on Tool Path, Surface Roughness, and Cycle Time During Multi-Axis CNC Milling Machining of Radial Camshaft

In olden days, for manufacturing camshafts, they used conventional methods like casting, forging and CNC technology for the creation of the radial camshaft and these processes have several disadvantages. The advancement in cnc machining has reached the concept of multi-axis cnc machining technology which results in several benefits in machining complex components. The main benefits of multi-axis cnc machining are reduced setups, improved surface finish, improved tool life, reduced cycle time, improved productivity and reduced overall machining cost. Proper selection and verification of the machining parameters give the selection of optimized tool paths (reduced cycle time and collision-free) in Mastercam software before real-time machining can cause unwanted accidents and collisions. This works deals with the three-axis rough machining of the radial camshaft using proper tool path, and four-axis machining of the radial camshaft by applying three varying machining parameters (spindle speed, feed rate, depth of cut) on three cams using three cutters. We carry investigation on surface roughness and cycle time in the finishing operation out on three cams. We complete the constant overlap spiral method to be the best tool path for roughing operation for the analyzed geometry. Cam-c results in the better surface finish, cam-a result in optimized cycle time in the finishing operation. Finally, the machining parameters used for cam-a and cam-c can be considered for getting the benefits of multi-axis machining technology.