A new tool-path generation method using a cylindrical end mill for 5-axis machining of a spatial cam with a conical meshing element

The geometry of a spatial cam is normally generated using a form-milling cutter and a special multi-axis machine and software. The general purpose CAD/CAM software can generate the cutter location file of this class of product only by the sculpturing method. Because of the limited choice of cutting tool when using the generating method, this paper presents a new toolpath generating method which combines the advantages of the generating and sculpturing methods for machining a spatial cam. In the machining process, the cutter location is derived for rough and finish machining using a cylindrical end mill. The guidelines for choosing cutter diameter for the machining process are discussed. To avoid interference, the principal curvatures and the principal induced normal curvatures are analysed. The mathematical errors including chordal deviation and scallop height are used as the basis for generating appropriate tool-paths. Cutting simulation of a solid model was performed to verify the proposed tool-path generation method.