5-axis Flank Milling Research Articles

Tool path planning for 5-axis flank milling of ruled surfaces considering CNC linear interpolation

This paper investigates tool path planning for 5-axis flank milling of ruled surfaces in consideration of CNC linear interpolation. Simulation analyses for machining error show insights into the tool motion that generates a precision machined surface. Contradicting to previous thoughts, the resultant tool path does not necessarily produce minimal machining error when the cutter contacts the rulings of a developable surface. This effect becomes more significant as the distance between two cutter locations is increased. An optimizing approach that adjusts the tool position locally may not produce minimal error as far as the entire surface is concerned. The optimal tool path computed by a global search scheme based on dynamic programming supports this argument. A flank milling experiment and CMM measurement further validate the findings of this work.

New approach to 5-axis flank milling of free-form surfaces: Computation of adapted tool shape

This paper develops a new approach to solve the problem of interferences during the flank milling of a non-developable ruled surface. Many articles propose to modify the tool path to reduce this problem. A novel approach is proposed here, Computation of Adapted Tool Shape (CATS), which computes and optimizes the tool shape to reduce these interferences. The aim of this CATS method is to maintain a standard CAM system thanks to the tool shape modification. This method is presented for the machining of an industrial part and for a numerical experimental design of nine surfaces.

Geometrical deviations versus smoothness in 5-axis high-speed flank milling

The paper deals with the Generation of Optimized 5-aXis Flank milling trajectories. Within the context of 5-axis High-Speed Machining, oscillatory trajectories may penalize process efficiency. The control of the trajectory smoothness is as essential as the control of geometrical deviations. For this purpose the Geo5XF method based on the surface representation of the tool trajectory has been developed. In flank milling, this surface, also called the Machining Surface (MS), is the ruled surface locus of the tool axes defining the trajectory. Based on a first positioning, the method aims at globally minimizing geometrical deviations between the envelope surface of the tool movement and the designed surface by deforming the MS while preserving trajectory smoothness. The energy of deformation of the MS is used as an indicator of the smoothness. Hence, in most cases, results obtained using Geo5XF show that minimum energy tool paths lead to minimal machining time. As geometrical deviations are not minimized for minimum energy tool paths, a compromise must be reached to find the best solution.

Research on the Plunge Milling Techniques for Open Blisks

In order to improve the efficiency and quality in rough milling for open blisks, the plunge milling strategy is a good choice instead of the traditional 5-axis point milling and flank milling for deep and narrow channels machining. Theory and procedures of using a ruled surface to approximate a freeform surface are presented based on the theory of minimum area. The plunge milling strategy is discussed and developed for open blisks. And the NC programs of plunge milling is further developed and verified based on the UG software. At the end, the open blisk test piece was machined by plunge milling. The result reveals that high-speed plunge milling has increased efficiency greatly in the open blisks rough milling than the traditional methods.

Improved positioning of cylindrical cutter for flank milling ruled surfaces

An optimized positioning procedure for flank milling ruled surfaces with cylindrical cutter is described in the paper. The tool axis trajectory surface is a ruled surface, which is generated by moving the tool axis. The proposition that the envelope surface of cylindrical cutter is the offset surface of tool axis trajectory surface is proved using kinematics approach. It is a complement of Bedi's [Bedi S, Mann S, Menzel C. Flank milling with flat end cutter. Comput Aided Des 2003; 35:293–300] analysis about the envelope surface of cylindrical cutter. Subsequently, we get another proposition that the deviation at extremum point between the designed surface and the envelope surface of cylindrical cutter is equal to that between the offset surface of designed surface and the tool axis trajectory surface. Based on this proposition, we propose three points offset (TPO) strategy to approximate the offset surface. In order to reduce errors further, a simple least square approximation scheme is established to make the tool axis trajectory surface fit the offset surface of designed surface as much as possible. By solving the linear system of equations, the tool axis trajectory surface is deformed. Simultaneously, the corresponding envelope surface is deformed to approximate the designed surface better. Two examples are given to verify the effectiveness of the developed 5-axis flank milling technique.

Accurate 5-Axis Machining of Twisted Ruled Surfaces

Flank cutting can be effectively employed to machine ruled surfaces instead of traditional point cutting. In consideration of reducing discrepancies between designed and machined twisted ruled surfaces, an analytical model is established to account for undercutting incurred in flank milling by the use of cylindrical cutters. Based on the model, the twist angle, the ruling length, and the size of the used cutter relating to the magnitude of undercutting are observed. By flank milling twisted ruled blade surfaces of an impeller, an application example is given to show the developed 5-axis flank milling technique based on a type of a 5-axis machine tool.