Toolpath optimization for 3-axis milling of thin-wall components

Milling of thin-wall components often entails significant workpiece static deflections, which make manufacturers use conservative cutting parameters along the toolpath to meet the tolerance required. This paper presents a technique to define the 3-axis toolpath that maximizes cutting parameters, without compromising the accuracy of the component. This goal is achieved by coupling a FE model of the workpiece, updated to include material removal mechanism, to a mechanistic model of the cutting forces. The algorithm follows the milling cycle in the reverse order: starts from the finished part, computes the maximum allowable radial depth of cut, and adding material accordingly, generates the toolpath until the stock is build. The proposed technique has been experimentally validated through comparisons between milling tests and numerical results, both traditional and optimized toolpaths have been tested to assess accuracy, benefits and limitations of the method.