Computer Aided NC Tool Path Planning for 3-Axis Vertical Milling Using Conical Tool

Abstract

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. Today, the availability of powerful and low cost 3D tools provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organizations. Mass Customization is a paradigm that produces custom products in masses. Although process planning for mass customized products is same, the tool path required to CNC machine the custom feature varies from part to part. If the tool path is created manually the economics of mass production are challenged. The only viable option is to generate the tool path automatically, furthermore, any time savings in the tool path lead to increase in profit margins. The thesis presents a tool path planning approach for the conical end milling cutter having same taper angle to that of surface to be machined. An algorithm has been developed for 3-axis vertical milling machine using parametric equations, which has not been discussed previously for conical cutter. A zig-zag tool path foot print has been developed to attain a better surface finish on the machined part. The tool path generated is then experimentally validated by cutting a single profile with conical cutter, ball nose cutter and cylindrical end milling cutter. The resulting cavities are then tested and compared for roughness. The result validates the tool path foot print and shows that finishing achieved by using conical end milling cutter is better than the other two cutters.