Cutting Tool Path Modification to Uniform Scallop‐Height in Three-Axis Milling Operations

Abstract Scallop height, which is the uncut amount of workpiece materials in metal cutting paths, has an impact on the surface condition of manufactured products. To increase accuracy and surface quality of machined parts, the scallop height should be analyzed in order to be minimized. In this study, a virtual machining system is created to produce uniform scallop height throughout free form surface end milling. Machined surfaces are analyzed by the developed system in order to obtain the curvature of free form surfaces. Then, the machined surfaces are divided to the flat, concave and convex surfaces in order to analyze and modify the cutting tool paths along milling operations. The machining parameters of step over, feed rate and spindle speed are modified in order to obtain uniform scallop height during milling operations of free form surfaces. As a result, the modified cutting tool paths can generate the uniform scallop height in order to increase surface quality of machined free form surfaces. To enhance the process of component manufacturing utilizing machining operations, the study's produced virtual machining system can raise the productivity as well as the accuracy of machined free from surfaces.