5-axis High Speed Milling Optimisation

TL;DR

This paper introduces a novel surface representation model for 5-axis High Speed Milling that integrates machine constraints early in tool path calculation, optimizing performance and avoiding issues like gouging.

Contribution

It presents a new bi-parameter surface model for 5-axis HSM tool path optimization, incorporating machine constraints during initial computation stages.

Findings

Enhanced tool path quality with integrated constraints

Increased productivity through optimized path calculation

Effective avoidance of gouging and singularities

Abstract

Manufacturing of free form parts relies on the calculation of a tool path based on a CAD model, on a machining strategy and on a given numerically controlled machine tool. In order to reach the best possible performances, it is necessary to take into account a maximum of constraints during tool path calculation. For this purpose, we have developed a surface representation of the tool paths to manage 5-axis High Speed Milling, which is the most complicated case. This model allows integrating early in the step of tool path computation the machine tool geometrical constraints (axis ranges, part holder orientation), kinematical constraints (speed and acceleration on the axes, singularities) as well as gouging issues between the tool and the part. The aim of the paper is to optimize the step of 5-axis HSM tool path calculation with a bi-parameter surface representation of the tool path. We propose an example of integration of the digital process for tool path computation, ensuring the required quality and maximum productivity