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

Jean-Max Redonnet (1) , Alejandro Gamboa Vázquez (2) , Alberto Traslosheros Michel (2) , Stéphane Segonds (1)

1 ICA - Institut Clément Ader
2 Universidad Aeronáutica en Querétaro

Machining by parallel planes is a widely used strategy for end milling of free-form surfaces on 3-axis Numerically Controlled (NC) machine. In industry, this type of machining is generally performed with a hemispherical tool. However, numerous studies have shown the benefits of torus end mill on 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 machining of free-form surfaces. This paper presents an optimisation of part machining direction allowing minimizing the machining time within the respect of the maximum imposed scallop height. This optimisation 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 no optimized direction.

Mots clés: effective tool radius; torus-end mill; CNC machine-tool; optimisation; workpiece orientation; free-form surface

Domaines: Génie mécanique [physics.class-ph]; Génie des procédés

Jean-Max Redonnet, Alejandro Gamboa Vázquez, Alberto Traslosheros Michel, Stéphane Segonds. Optimisation of free-form surface machining using parallel planes strategy and torus milling cutter. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016, 232 (2), pp.240-250. ⟨10.1177/0954405416640175⟩. ⟨hal-01913381⟩