Influence of Ball-End Milling Strategy on the Accuracy and Roughness of Free Form Surfaces

Freeform surfaces are present on an increasing number of engineering products. Three- and multi-axis computer numerical control milling machines are commonly used for improved production. Computer-aided manufacturing (CAM) systems are used almost exclusively for the creation of programs for a variety of machining centers. This study compared the quality of freeform surfaces made by 3- and 5-axis milling using three commonly used strategies (linear, offset, and spiral). The CAM system-predicted surfaces were also compared with the actual surfaces. A test sample with a freeform surface was used for the experiments. Considering the size and distribution, the discrepancy between the predicted surface deviations and the deviations in the produced samples was proven. Maximum negative surface deviations, when 5-axis milling, employed linear and spiral strategy of 29% and 71% less than those produced by the 3-axis milling. On the contrary, positive deviations were 48% smaller. A comparison of the scans showed that the two strategies (linear and spiral) yielded better results for 5-axis milling, and the offset strategy was better for 3-axis milling. Evaluation of the achieved surface roughness showed that the milling method did not significantly affect the surface quality in the linear strategy. However, other two strategies (offset and spiral) achieved better results with 5-axis milling compared to 3-axis milling. The proposed method of evaluating the accuracy of machined free form surfaces can be used in experimental as well as production activities.

Automated summary

This study compared the quality of freeform surfaces made by 3- and 5-axis milling using three commonly used strategies. The results showed that 5-axis milling with linear and spiral strategies had smaller negative deviations compared to 3-axis milling, while positive deviations were 48% smaller. Evaluation of surface roughness showed that the milling method did not significantly affect surface quality in the linear strategy, but the offset and spiral strategies achieved better results in 5-axis milling compared to 3-axis milling.