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End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

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journal contribution
posted on 2015-09-28, 10:28 authored by Muhammed Nafis Osman Zahid, Keith Case, Darren WattsDarren Watts
Computer Numerical Controlled (CNC) machining has been recognized as a manufacturing process that is capable of producing metal parts with high precision and reliable quality, whereas many additive manufacturing methods are less capable in these respects. The introduction of a new layer removal methodology that utilizes an indexing device to clamp the workpiece can be used to extend CNC applications into the realm of rapid manufacturing (CNC-RM) processes. This study aims to improve the implementation of CNC machining for RM by formulating a distinct approach to integrate end mill tools during finishing processes. A main objective is to enhance process efficiency by minimizing the stair-casing effect of layer removal so as to improve the quality of machined parts. In order to achieve this, different types of end mill tools are introduced to cater for specific part surfaces during finishing operations. Virtual machining simulations are executed to verify the method and the implications. The findings indicate the advantages of the approach in terms of cutting time and excess volume left on the parts. It is shown that using different tools for finishing operations will improve the capabilities of CNC machining for rapid manufacturing applications.



  • Mechanical, Electrical and Manufacturing Engineering

Published in

Production and Manufacturing Research


OSMAN ZAHID, M.N., CASE, K. and WATTS, D.M., 2015. End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies. Production and Manufacturing Research, 3 (1), pp. 274–288.


© The Author(s). Published by Taylor & Francis


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This work is made available according to the conditions of the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0) licence. Full details of this licence are available at: https://creativecommons.org/licenses/by-nc-nd/4.0/

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This paper was published by Taylor & Francis in the Open Access journal Production & Manufacturing Research. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (http://creativecom mons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.




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