Undevelopable ruled surface flank milling cutter path optimization algorithm

Aimed at the calculation problems of cutter axis vector in flank milling of undevelopable ruled surface, the mechanism of machining error of undevelopable ruled surface based on the geometrical error mode is analyzed. To improve the machining precision of undevelopable ruled surface, an optimization method is established to obtain the optimal computational method of tool axis by studying of the double points offset and three points offset algorithms. In addition, based on the least-square method, the further optimization of tool path is proposed. With this method, the machining error in the contact zone of the tool and the machined surface can be minimized, and an overall optimization of tool path can be further generated. Experimental results show that the machining error related to the proposed method is significantly lower than that associated with the existing methods, and confirm the correctness and reliability of the method. The methods and data results provide a theoretical reference for the flank milling of undevelopable ruled surface. © 2014 Journal of Mechanical Engineering.