A hybrid analytical and discrete based methodology to calculate path scallop of helical toroidal cutter in five-axis milling

Abstract

This paper presents a new method to calculate path scallop height of toroidal cutter during free-form surface machining in five-axis milling. The scallop height was defined as the distance between the tool intersection point and the normal point on the part surface. The tool intersection point was determined analytically by implementing the grazing method to define the swept curve of toroidal cutter. Meanwhile the normal surface on the part surface was determined using a hybrid analytical and discrete based methodology. The part surface was discretized by a number of normal vectors, then, they were used for defining the part surface mathematically. In this study,the effect of helical angle of cutting edge was taken into consideration in the model development. The proposed model was successfully used to generate the path scallop data for two model parts with free-form surface profiles. The effect of helical angle to the scallop height was also tested and the results showed that the helical angle tends to decrease the scallop height. The verification test to check the accuracy of the proposed method was performed and the results proved that the method was accurate.

Path Interval and Its Relevance to Cutting Force in Ball and Filleted End Milling

“…In ball end milling, the path interval can be calculated based on an intersection problem between a designed shape and a cutting edge of ball end mill in a machining state [12][13][14][15]. In fl at and fi lleted end milling, there are the two kinds of procedures available to determine a proper path interval [16][17][18][19][20][21][22][23][24]. The one employs a two dimensional procedure considering a cutter profi le on an imaginary section introduced geometrically, and the other is a three dimensional computation based on a geometrical modeling of milling process.…”

Comparative Study on Path Interval and Two Tool Condition Parameters in Ball and Filleted End Milling

“…There are the similar research directions in fi lleted end milling. A few studies with the path interval determination raise a two dimensional intersection problem considering a relationship between designed shape and cutting edge projected instantaneously onto an arbitrary section [22][23][24], whereas the related studies are mostly based on three dimensional expression designed mainly for a computational procedure to overcome mathematical complexities [25][26][27]. Among them, a procedure with remarkable characteristics was reported to determine a proper path interval in multi-axis fi lleted end milling [28].…”