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<p>In manufacturing context a free-form surface is a surface that is neither prismatic nor of revolution. End-milling of free-form surfaces on multi-axis CNC (Computer Numerical Control) machines is a complex and expensive operation involved in the production of many high-value-added parts, such as molds and stamping dies. For such operations, the toolpath planning process is important because it has a very high impact on operation duration and, thus, on the cost of the part. The objective of this process is to minimize the machining time while ensuring the surface quality. Roughly speaking, it aims to make a good part as quickly as possible. This article presents a comprehensive method for optimizing 3+2 axis milling of free-form surfaces using a toroidal cutter. It is based on a partition of the surface into zones, which are then optimally oriented for machining with a toroidal tool using a parallel-plane strategy. We implemented the whole method in our software package named <b>CoSMO</b> (<b>Co</b>mplex <b>S</b>urface <b>M</b>achining <b>O</b>ptimization). The results obtained by this software are compared with those of an industrial software driven by a CAM (Computer-aided Manufacturing) expert. On the experimental part, the gain in machining time is around 50%. Moreover, this experiment is presented with all the information needed for comparison with future contributions to the field.</p>

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A comprehensive method to optimize 3+2 axis end-milling of free-form surfaces with a toroidal cutter

  • 期刊论文

  • 发表日期：

    2026年4月14日

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  • Jean-Max Redonnet,
  • Marcel Mongeau,
  • Guillaume Cohen,
  • Mahfoud Herraz,
  • Mohammed Sbihi

摘要

In manufacturing context a free-form surface is a surface that is neither prismatic nor of revolution. End-milling of free-form surfaces on multi-axis CNC (Computer Numerical Control) machines is a complex and expensive operation involved in the production of many high-value-added parts, such as molds and stamping dies. For such operations, the toolpath planning process is important because it has a very high impact on operation duration and, thus, on the cost of the part. The objective of this process is to minimize the machining time while ensuring the surface quality. Roughly speaking, it aims to make a good part as quickly as possible. This article presents a comprehensive method for optimizing 3+2 axis milling of free-form surfaces using a toroidal cutter. It is based on a partition of the surface into zones, which are then optimally oriented for machining with a toroidal tool using a parallel-plane strategy. We implemented the whole method in our software package named CoSMO (Complex Surface Machining Optimization). The results obtained by this software are compared with those of an industrial software driven by a CAM (Computer-aided Manufacturing) expert. On the experimental part, the gain in machining time is around 50%. Moreover, this experiment is presented with all the information needed for comparison with future contributions to the field.