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<p>To address poor machining quality in complex surface processing, this study proposes an innovative tool design method based on workpiece-tool surface matching. By analyzing local geometric properties of the workpiece surface, the complex surface is decomposed into multiple regions, and the tool’s end generatrix is defined by tangent circular arcs with optimized geometric parameters through curvature constraints and global matching optimization. An exemplary four-arc milling cutter is designed, featuring a tool-end generatrix composed of four precisely optimized tangent circular arcs with radii of <i>r</i><sub>1</sub> = 6.44 mm, <i>r</i><sub>2</sub> = 5.05 mm, <i>r</i><sub>3</sub> = 3.78 mm, and <i>r</i><sub>4</sub> = 1 mm. This innovative design significantly enhances both cutting edge utilization and effective cutting speed. Experimental results demonstrate superior surface quality compared to conventional ball end milling cutter under identical machining conditions, reducing average and maximum machining errors by 25.0% and 24.7%, respectively. This method validates the effectiveness of surface-matching-based tool design in enhancing machining quality, offering a new idea for the design of high-quality and high-precision machining tools.</p>

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Research on an innovative tool design method based on workpiece-tool surface matching

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Mengchao Fan,
  • Wenhao Song,
  • Caixu Yue,
  • Xianli Liu,
  • Yaopeng Zhang

摘要

To address poor machining quality in complex surface processing, this study proposes an innovative tool design method based on workpiece-tool surface matching. By analyzing local geometric properties of the workpiece surface, the complex surface is decomposed into multiple regions, and the tool’s end generatrix is defined by tangent circular arcs with optimized geometric parameters through curvature constraints and global matching optimization. An exemplary four-arc milling cutter is designed, featuring a tool-end generatrix composed of four precisely optimized tangent circular arcs with radii of r1 = 6.44 mm, r2 = 5.05 mm, r3 = 3.78 mm, and r4 = 1 mm. This innovative design significantly enhances both cutting edge utilization and effective cutting speed. Experimental results demonstrate superior surface quality compared to conventional ball end milling cutter under identical machining conditions, reducing average and maximum machining errors by 25.0% and 24.7%, respectively. This method validates the effectiveness of surface-matching-based tool design in enhancing machining quality, offering a new idea for the design of high-quality and high-precision machining tools.