Optimization of free-form surface machining using parallel planes strategy and torus milling cutter

Abstract

Machining by parallel planes is a widely used strategy for end-milling of free-form surfaces on 3-axis numerically controlled machines. In industry, this type of machining is generally performed with a hemispherical tool. However, numerous studies have shown the benefits of torus-end mills over ball-end or flat-end mills. More than anything, the machining direction has much influence on productivity while using a torus-end mill. In this context, the choice of the machining direction is of paramount importance when using a torus-end mill in the machining of free-form surfaces. This paper presents an optimization of part machining direction allowing the machining time to be minimized while respecting the maximum imposed scallop height. This optimization methodology is then applied to an industrial part and measurements are performed on this part. The study highlights the interest of optimizing the machining direction and the benefits that can be drawn with respect to machining using a non-optimized direction.