5-axis CNC Whirlwind Milling Model for Complex Freeform Surfaces

Whirlwind milling model is a new milling technique proposed in this paper based on 5-axis CNC horizontal bed-type milling machines. The machining strategy of this model is to make a real-time adjustment of cutter orientation of whirlwind milling tool so as to create a close approaching envelopment to the surface being machined with the milling-tool rotational surface. Then, a full approach between these two surfaces can ensure maximizing the material removal on the machined surface at point of contact and improve the machining quality. A whirlwind milling tool with standard-sized circular edge cutters is introduced to side-mill complex freeform surfaces. The fundamentals, kinematics relationship, cutter location equations and tool path generation about this new milling model are analyzed, and some real application is presented