Research on a novel approach to multi-axis line contact milling

The principle of a novel multi-axis milling is presented. Peripheral edges of a cutter are in contact with the theoretical profile of a work-piece, and rotation of spindle drum imitates turning. Thus, the theoretical profile can be achieved with the minimum reciprocating movements of the cutter and the shortest cutter path length. It is a novel efficient Numerical Control (NC) machining approach that combines the high efficiency of line contact machining with low roughness of turning. A whole developable ruled surface can be processed with only one NC code by lifting, swinging, shifting, and rotating of the spindle drum. Two rotating movements adjust the vector of the cutter axis. The lifting of the spindle drum makes the tangent point of the cutter moves along the drive curve of surfaces while the peripheral edges of the cutter are tangent to the theoretical surfaces. The milling methods, efficiency and machining precision to process various curved surfaces are contrasted. Comparing the efficiency and machining accuracy in the approach with those of 5-coordinate point contact machining and 5-coordinate line contact machining, the results show that the approach excels the others.