Toolpath Optimization To Enhance Machining Accuracy: A Case Study Of The Fabrication Of A Thermoform Mold.

Abstract

Scallop height is the most crucial factor for ensuring a smooth surface finish and maintaining consistent material removal across the machined surfaces during CNC machining operations. The study proposes an innovative approach that involving categorize the free-form surface in to flat, convex, and concave and adjust the toolpath and machining strategy accordingly by computing and optimizing machining variables of feed rate, speed of spindle and step over. This approach helps to reduce material waste, tool wear and part production errors while ensuring consistent and high-quality machined parts and reduce chatter and vibration during milling operations. A case study of the fabrication of a thermoform mold using Mastercam software is carried out to validate the findings in this research.