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Ball-end mill (3-axis) machining is a proven, yet inefficient, material removal process for machining surfaces defined within a cavity. Curvature matched (5-axis) machining (CM2) is a proven efficient material removal process for large free-form surfaces, but has primarily been applied to open surfaces. This paper presents a robust algorithm that blends CM2 machining with traditional three-axis ball-end machining to accurately mill free-form surfaces enclosed by cavity walls. Surfaces once inaccessible to CM2 methods can now be effectively machined, while inaccessible regions are prepared for automatic ball-end mill machining. Results of time saving and the percentage of the surface machined using each method are presented.

Machining Free-Form Surface Cavities Using a Combination of Traditional and Non-Traditional Multi-Axis Machining Methods