New approach to 5-axis flank milling of free-form surfaces: Computation of adapted tool shape

This paper develops a new approach to solve the problem of interferences during the flank milling of a non-developable ruled surface. Many articles propose to modify the tool path to reduce this problem. A novel approach is proposed here, Computation of Adapted Tool Shape (CATS), which computes and optimizes the tool shape to reduce these interferences. The aim of this CATS method is to maintain a standard CAM system thanks to the tool shape modification. This method is presented for the machining of an industrial part and for a numerical experimental design of nine surfaces.