Abstract
A new category of 5-axis flank computer numerically controlled (CNC) machining, called double-flank , is presented. Instead of using a predefined set of milling tools, we use the shape of the milling tool as a free parameter in our optimization-based approach and, for a given input free-form (NURBS) surface, compute a custom-shaped tool that admits highly-accurate machining. Aimed at curved narrow regions where the tool may have double tangential contact with the reference surface, like spiral bevel gears, the initial trajectory of the milling tool is estimated by fitting a ruled surface to the self-bisector of the reference surface. The shape of the tool and its motion then both undergo global optimization that seeks high approximation quality between the input free-form surface and its envelope approximation, fairness of the motion and the tool, and prevents overcutting. That is, our double-flank machining is meant for the semi-finishing stage and therefore the envelope of the motion is, by construction, penetration-free with the references surface. Our algorithm is validated by a commercial path-finding software and the prototype of the tool for a specific gear model is 3D printed. • We introduce a new 5-axis flank CNC machining methodology called double-flank milling. • The shape of the tool is an unknown in our optimization approach. • The methodology is well suited for narrow regions like spiral bevel gears. • Our approach is validated by a commercial CNC path finding software. • The prototype of the tool for one particular gear geometry is 3D-printed.
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