Simulation of Toolpaths Using 3D Method Strategies for Complex Shape in Milling Application

Abstract

Several strategies can be used for machining complex 3D shapes on a 3-axis CNC vertical milling machine in Autodesk Inventor Professional software. However, it is challenging to determine suitable strategies without guidance. Among the strategies involved are Scallop, Radial, Spiral, and Morphed Spiral. The purpose of this study is to compare the toolpaths strategy in terms of machining time by using high-speed machining parameters. A hemisphere shape and a fillet feature in the part are considered complex shapes due to their convex and concave surfaces. There are two step machining processes involved, which are roughing and finishing. Comparison time is focused on finishing the process using those strategies. Actual fixed machining parameters like tool diameter, feed rate, spindle speed, stepover, and cutting depth are used to make simulations of the toolpaths. Based on the simulation, the radial strategy has the shortest machining time and cutting length by more than fifty percent (50%) compared to other strategies. This is due to the fact that this technique generates passes along the arc's radii, which are subsequently projected down on the surfaces. The passes can be linked in a zig-zag pattern between the outer and inner radius, either from inside to outside or outside to inside. However, collisions between the cutting tool and the workpiece must be closely monitored. As a result, cutting length must also be addressed when deciding to use this strategy. In conclusion, high-speed machining with the right machining strategy is essential for increased productivity.