Definition of tailor made cutting tools for machining of complex surfaces based on final surface shape

In this work a design methodology to define the best geometry of cutting tool for complex surfaces is defined, being based on the final part surface geometry. The manufacture of components with tailor made shaped tools, based on algorithm calculation and adapted to the geometry of the final piece surface, reduces manufacturing time and maintains piece quality in comparison with traditional cutting tools. Cutting tools are usually cylindrical (end mills) or ball-end mills. With mathematical algorithms can be defined diamond & CBN electroplated form tools, multi-tooth endmills, abrasive grinding tools and so on. The approach here presented can enable the production of tools for manufacturing process such as Super Abrasive Machining (SAM) and Flank milling strategies. Comparison between standard tools and traditional machining processes versus custom-shaped tools was studied in terms of process time. Final applications are numerous, such as, integral blade rotors, spiral bevel gears, blisks and impellers, complex screws, and others.