Machining Time Reduction by Tool Path Modification to Eliminate Air Cutting Motion for End Milling Operation

Abstract

A method to uniquely calculate the tool path and to modify the tool path during air cutting motion to reduce the machining time is proposed. This study presents a contour line model, in which the product model is minutely divided on a plane along an axial direction, and the contour line of the cross-section of the product is superimposed. A method is then proposed to calculate the tool position according to the degree of interference between the product surface and the tool. Furthermore, this study proposes a technique to reduce the machining time by tool path modification during air cutting motion. This is determined by the geometric relationship between the product surface and the tool, and not based on cutting simulations. A cutting experiment was conducted to validate the effectiveness of the proposed method. Based on the results, it was confirmed that the difference in machining time between the tool path with modification and the tool path without modification was large. Moreover, the machining time was significantly reduced by the tool path modification. The results showed that the proposed method has good potential to perform customized manufacturing, and to realize both high productivity and reliability in machining operation.