Five-axis milling of rough and PBF-LB parts with free-form surfaces using ball-end and circle-segment end mills

Abstract

This Ph.D. thesis investigates the manufacturing processes of complex geometrical shapes, focusing on the milling process of free-formed surfaces with ball-end tooltips. This kind of surface is commonly present in high-value-added products like turbofan blades and BLISK components, and manufacturing deviation can decrease durability and performance, making the prediction of the surface texture and dimensional errors important. This work covered several topics related to finishing components containing free-form surfaces. The influences of the material, cutting contact, cutting parameters, equipment, and tooltip influence are investigated.