CNC Milling for 3D Complex
Curved Surfaces
The Gundan Head Armour is composed of several complex surfaces, making it hard to process. To maximize the accuracy of our work piece, we analyze and choose the best tool path as well as the suitable machining tools under different surfaces. Using a simple 3-axis milling machine, rather than any 5 or more axis machine is really cost-efficiency. This process also makes massive production possible. |
Creation Concept and Product Applications:
The most distinctive part of this product is that the complex surface can be done by using a simple 3-axis Milling machine. Most of time, using 5-axis Machine is able to decrease the risk of crash on milling tools when the depth is too deep and enhance the accuracy of the surface; however, we achieve the same accuracy and complete the same task by tuning parameters as well as the optimal arrangement of tool’s path on 3-axis machine. By this way, we can handle the complex surface under the limitation of types of tools and materials. Besides, this method can also be applied widely such as mold production with lots of complex surfaces.
Used Tools, Accessories and software:
We use 3-axis milling machine with the Fanuc controller to produce our product. Before processing, the material is produced by the manual milling machine. The work piece is made of Aluminum with the dimension of 50*50*53 mm^3. We also use Solidworks to finish the Helmet CAD model and use Photoview and Keyshot4.0 to do the simulation. For tool path generation, we chose to use both Cimatron and MasterCam to combine the advantages of each other in order to achieve the maximum accuracy and efficiency.
Cutting Tools:
According to our original CAD, All the bottoms of these grooves are designed as right angles to the sidewall. By using the flat end mill, there is no doubt that we can easily attain this goal because the end of the flat end mill is perpendicular to the tools body. However, it will create terraced errors when cutting a curved surface. In contrast, by using ball mill, take a 1mm ball mill for example; its round radius is 0.5mm. Since there is only a contact point between the cutting tool and surface, it will have much better precision on surface. Nevertheless, when milling the button, it will round the corner with 0.5 radiuses automatically. Using the round end mill will adopt two advantages of the cutting tools mentioned above. Take a 2mm radius round end mill for instance. It will still remain a contact point between the surface and tool. Besides, the round radius in the bottom will decrease to 0.2 mm much closer to the right angles.
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