A General Mathematical Model for Whirlwind Milling Technique Machining Complex 3D Surfaces

Abstract Machining complex three-dimensional surfaces high-productively and effectively is a challenging task. The whirlwind milling technique is a new milling model proposed in this paper based on 5-axis CNC bed-type horizontal milling machine. Its milling cutter head is similar to a shallow disk, and its cutting lip consists of about two dozens of standard turning-tool cutters. It is easy for this whirlwind milling cutter to avoid gouging and tool interference because of its very narrow cutter width and sharp cutter tooth tip. Moreover, the machining strategy of this new technique is able to align principal curvatures of the machined surfaces with that of cutter tool rotational symmetric surface to generate a close fit. So, it can increase the metal removal rate (MMR) at the point of contact and enhance the milling productivity. The essential characteristics of this technique such as its working mechanism, kinematic relationship, fundamental milling equation and cutter location data, are discussed in details. The new proposed method has been used in practical process of manufacturing complex 3D surfaces in petroleum industry.