Tool path generation for milling of free form surfaces with feedrate scheduling

The use of freeform (sculptured) surfaces in the product design process is accelerating at an exponential rate driven by functional as well as esthetics demands. CAD/CAM software is a must in their design and manufacture. While the geometric aspects of the design are relatively wellcovered, issues still remain when it comes to the actual manufacture of freeform surfaces. The major issues are related to the generation of the proper toolpaths that would assure the required surface quality, the minimization of the total maching time, the control of the magnitude of the cutting forces, etc. This paper presents an algotithmic procedure for tool path generation based on the criterion of maintaing the cutting forces at a constant pre-defined level for 3-axis ball end milling processes. To this end, a model for cutting force prediction is formulated and incorporated into the tolpath generation algorithm and software that is compatible with all CAD/CAM systems. It has been experimentally confirmed that the proposed algorithm offers a number advantages over the machining strategies used in commercial CAD/CAM software.