Adaptive Milling of Free-Form Surfaces with Circle Segment End Mills

This thesis investigates the adaptive milling of free-form surfaces with circle segment end mills to improve machinability. Basic milling tests and a high-precision mechanistic engagement and force simulation are used to analyze the influence of surface topography and tool orientation on machinability. Process rules are derived to reduce force fluctuations and implemented in CAM-based strategies to enhance productivity and support the industrial application of circle segment end mills.