Optimisation of free-form milling with ball-end tools through computational manufacturing

forthcoming

Free-form surfaces are present in key industries such as aerospace, automotive, and energy, fulfilling both aesthetic and functional requirements. Ball-end milling is preferred for manufacturing due to its high efficiency and precision. However, the large number of variables makes the process challenging and not fully understood. The intermittent cutting characteristics, along with changes in tool-workpiece contact and variations in effective cutting speed, are some of the difficult aspects to predict that significantly impact surface quality and part accuracy. Additionally, depending on the tool orientation, the transition between ploughing and shearing as the predominant mechanisms can occur, with the transitional zone not being well understood. This research proposes the development of a robust methodology to integrate predictive mathematical models into commercial CAD/CAM software, enhancing the precision of ball-end milling of free-form geometries. The project will focus on understanding the cutting phenomena, particularly the transition between shearing and ploughing, and implementing cutter workpiece engagement (CWE), and the cutting forces within the CAM software environment for finishing operations with ball-end mills. The expected outcomes include new insights into the milling process, a robust methodology for modelling outputs, and the development of an API capable of predicting machining outcomes. This will provide tools for improving programming efficiency, reducing waste, and aligning with sustainability goals, thereby enhancing the academic understanding of the process and the competitiveness of the industry.