Tool Path Strategies for Efficient Milling of Thin-Wall Features

The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential 5-axis milling...

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Bibliographic Details
Published in:Journal of Manufacturing and Materials Processing 2024-08, Vol.8 (4), p.169
Main Authors: Tunc, Lutfi Taner, Gulmez, Deniz Arda
Format: Article
Language:English
Subjects:
5-axis milling
CAD/CAM
Chatter
Compliance
Cutting tool paths
Dynamic structural analysis
Efficiency
Finishing
Geometry
milling
Optimization
Simulation
stability
thin wall
Vibration
Workpieces
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Summary:The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential 5-axis milling tool path strategies, which do not exist in the conventional tool path generation. The demonstration is performed for increased efficiency in milling of thin-wall features considering the main limitation of chatter. The effects of varying workpiece dynamics on milling stability are shown in case studies through simulations and cutting experiments. Based on the simulation results, tool path strategies are developed. The effect of tool path generation and the relation to parameter selection are highlighted. Most of the discussion relies on previously reported experimental results. The results showed that by tailoring the tool path considering the concerns and limitations associated with thin-wall part structure and geometry, it is possible to increase productivity by at least two folds.
ISSN:2504-4494
2504-4494
DOI:10.3390/jmmp8040169