Pre-polishing and polishing stages are considered as semi-finishing and finishing stages in workpiece production. As a rule, these operations are carried out manually. These stages are health hazards for the operator and may lead to geometrical defects on workpieces. This paper proposes and optimizes a method to perform these operations on a common 5-axis milling machine. This method uses the flank of a flexible cylindrical tool to link the machine position and the exerted polishing pressure. The toolpath proposed comprises a carrier trajectory on which a loop pattern is repeated. Subsequently, experimental optimization of the pre-polishing cost is proposed, coupled with an estimation of the roughness obtained. Firstly, a screening Design Of Experiments is used to identify the most influential factors of this process. Based on these influential factors, a response surface is used to obtain experimental models to estimate the pre-polishing cost per volume and resulting roughness. These models are used to optimize the pre-polishing factors to reduce the process cost whilst maintaining specific roughness.
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