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Proceedings of CAD'16, 2016, 81-86
Optimal Tool Orientation Generation and Chip Volume/Cutting Force Predictions for 5-axis CNC Machining of Free-form Surfaces Using Flat-end Mills
Abstract. 5-axis CNC machining is widely used to produce various components with complex curved surfaces while potentially providing better tool accessibility to complex surfaces, producing more accurate surface, increasing material removal rate, and reducing machine setup time. Today, to avoid cutter-part surface interference/gouge at large curvature areas and to simplify toolpath/orientation planning, a small diameter ball-end mill is used during machining. This leads to low machining efficiency and large cusps for areas of the surface with small curvature. Large diameter end cutters present a more rigid and capable tool with a varying cutter curvature from the radius of the cutter to infinity (in principle) to support better cutter-part curvature match, leading to much improved machining efficiency and surface quality. Therefore, it is more beneficial to use flat-end mills for curved surface machining and to plan to tool path and tool orientation with the best curvature match between the cutter and the machined surface at the cutter contact (CC) point.
Keywords. 5-axis CNC, Tool orientation, EMS, Tri-dexel, Free-form Surface, Flat-end Mills, Chip Volume, Cutting Force