Adaptive optimizing tool orientation method for 5-axis toroidal-end milling of free-form surfaces

This paper focused on the 5-axis milling of free-form surfaces with the toroidal-end cutter. First, the function between the machined strip width based on second order approximations and the tool orientation was constructed and analyzed. Second, according to the principle that the cutting shape of the cutter matches the designed surface at the cutter contact point, the inclination angle which satisfied the local millable condition was calculated automatically. Finally, the optimal tilt angle was determined by maximizing the machined strip width. Examples show that the algorithm presented herein is feasible and the results are with shorter tool path and efficiency.