Precise algebraic-based swept volumes for arbitrary free-form shaped tools towards multi-axis CNC machining verification

Geometry and tool motion planning for curvature adapted CNC machining

“…(ii) The shape of the milling tool (see also Fig. 2): flat-end [Fan and Ball 2014;Jerard 1994], ballend [Ikua et al 2001], toroidal (aka bull-nose) [Campa et al 2007;Roth et al 2001], and general [Engin and Altintas 2001;Machchhar et al 2017] cutting tools. (iii) The type of contact between the milling tool and the reference surface: single-(multi-) point milling in the case where the tool touches the surface at a single (several) point(s), and flank milling where the tool is in contact with the target surface along a curve (see e.g.…”

5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools — Part I: Modeling and simulation

“…It is therefore preferable to approximate a curved surface by an envelope of the milling tool directly, without inserting the simplifying step of approximating the surface by a ruled surface, followed by approximating the ruled surface by an envelope of a cone/cylinder [18]. One can describe an envelope of the milling tool using algebraic constraints and use an efficient subdivision solver [19]. Such an approach is computationally demanding, however, a full machining coverage as well as topological correctness is guaranteed by the solver.…”

5-Axis Double-Flank CNC Machining of Spiral Bevel Gears via Custom-Shaped Milling Tools – Part II: Physical Validations and Experiments

“…The purpose of this study is to further advance our recent geometric modeling simulations on 5-axis CNC machining with custom-shaped milling tools [10]. That is, the path-planning algorithm does not only look for optimal milling paths, but also for the shape of the tool [1,11,12]. While flank milling with curved (barrel) tools is known and possible for input freeform surfaces [13,10] simultaneous tangential contact on two sides requires a specific input geometry.…”