Machining Free-Form Surface Cavities Using a Combination of Traditional and Non-Traditional Multi-Axis Machining Methods

Abstract

Ball-end mill (3-axis) machining is a proven, yet inefficient, material removal process for machining surfaces defined within a cavity. Curvature matched (5-axis) machining (CM²) is a proven efficient material removal process for large free-form surfaces, but has primarily been applied to open surfaces. This paper presents a robust algorithm that blends CM² machining with traditional three-axis ball-end machining to accurately mill free-form surfaces enclosed by cavity walls. Surfaces once inaccessible to CM² methods can now be effectively machined, while inaccessible regions are prepared for automatic ball-end mill machining. Results of time saving and the percentage of the surface machined using each method are presented.

Keywords:

• five-axis machining
• global gouging
• tool path generation