An optimum 2.5D contour parallel tool path

Abstract

Although conventional contour parallel tool paths obtained from geometric information have successfully been used to produce desired shapes, they seldom consider physical process concerns such as cutting forces and chatter. In this paper we introduce an optimized contour parallel path that maintains a constant material removal rate at all times. The optimized tool path is based on a conventional contour parallel tool path. Additional tool path segments are appended to the basic path to achieve constant cutting forces and to avoid chatter vibrations over the entire machining area. The algorithm was implemented for two-dimensional contiguous end milling operations with flat end mills, and cutting tests were conducted to verify the performance of the proposed method.