Tool path deformation in 5-axis flank milling using envelope surface

Geometrical deviations versus smoothness in 5-axis high-speed flank milling

“…The method for Generation of Optimized 5-aXis Flank milling trajectories (Geo5XF) is an extension of the method developed in [11] and consists of four main steps: Initial tool positioning; Approximation of the tool axis extremities by two curves defining the two directrices of the MS; Calculation of the deviations between the envelope surface and the designed surface; Positioning optimization by deforming the MS (Fig.1). …”

“…More generally, the calculation method is directly linked to the method used for tool path generation [8], [9], [11], [17], [18].…”

“…In previous works, a surface-based approach for tool positioning in flank milling has been proposed in [11]. The method relies on a first positioning of the tool according to a two contact point method.…”

“…This leads to solve a large linear system. First results have shown the benefit of using the surface-based approach to improve tool positioning [11]. The control of the geometrical deviations is as essential as the smoothness of the calculated tool trajectory to ensure high performance machining.…”

Deviation of a machined surface in flank milling

“…Flank milling of free surfaces traditionally implies the generation of machining tool paths that will ensure an optimal laying of the presumed rigid tool on the surface to machine [1][2][3][4]. In flank milling with long tools, the geometrical errors generated by the tool deflection during the cutting process can be very significant.…”