An approach to tool path planning for layered plunge milling of free-form surface impeller channel

Impeller is widely used in modern industry and plunge milling is considered as the most effective way for rough machining of impeller channel. However, for extremely twisted blade, single layer milling may easily cause large machining allowance, which will influence cutting efficiency seriously. Therefore, a new approach to tool path planning for layered plunge milling of free-form surface impeller channel is presented. Firstly, a feasible method of machinability analysis of channel is given. Secondly, the layered model of plunge milling which relative to the maximum tool and tool length is constructed. And then according to the model, tool path of layered plunge milling could be planned. Finally, the generated tool path of single layer and layered plunge milling are simulated. Simulation result shows that the approach is appropriate and feasible to reduce the machining allowance and reduce the working load for the following semi-finishing and finishing milling.