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This paper presents an analytical method to calculate path scallop height during free-form surface machining with flat-end cutter in five-axis milling. In this study the effect of lead angle and tilt angle were taken into consideration in the calculation. The scallop height was determined from the coordinate of the path intersection point. Path intersection point is an intersection between the cutting tool of the current tooth path and the previous tooth path. One model part with free-form surface was tested to verify the validity of the proposed method, the result proved that the method was accurate.

Path Scallop Calculation during Free-Form Surface Machining with Flat-End Cutter in Five-Axis Milling