Control of the contact force in a pre-polishing operation of free-form surfaces realised with a 5-axis CNC machine

Abstract The challenge is to control the radial force applied during pre-polishing operations realised with milling machines. This permits managing the contact pressure between the tool and the machined surface. Since CNC machines are controlled in position but not force, a flexible tool is used to obtain a smooth connection between contact force and tool position. A Design Of Experiment demonstrates the major rule of the radial engagement. A 5-axis toolpath is proposed to optimise pre-polishing operations of free-form surfaces. It accounts for the real tool shape, thus improving the stability of contact force. Experiments are realised to validate the developments.