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Optimisation of free-form milling with ball-end tools through computational manufacturing

Objective

Free-form surfaces are present in key industries such as aerospace, automotive, and energy, fulfilling both aesthetic and functional requirements. Ball-end milling is preferred for manufacturing due to its high efficiency and precision. However, the large number of variables makes the process challenging and not fully understood. The intermittent cutting characteristics, along with changes in tool-workpiece contact and variations in effective cutting speed, are some of the difficult aspects to predict that significantly impact surface quality and part accuracy. Additionally, depending on the tool orientation, the transition between ploughing and shearing as the predominant mechanisms can occur, with the transitional zone not being well understood. This research proposes the development of a robust methodology to integrate predictive mathematical models into commercial CAD/CAM software, enhancing the precision of ball-end milling of free-form geometries. The project will focus on understanding the cutting phenomena, particularly the transition between shearing and ploughing, and implementing cutter workpiece engagement (CWE), and the cutting forces within the CAM software environment for finishing operations with ball-end mills. The expected outcomes include new insights into the milling process, a robust methodology for modelling outputs, and the development of an API capable of predicting machining outcomes. This will provide tools for improving programming efficiency, reducing waste, and aligning with sustainability goals, thereby enhancing the academic understanding of the process and the competitiveness of the industry.

Fields of science (EuroSciVoc)

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Keywords

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Programme(s)

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Topic(s)

Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.

Funding Scheme

Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.

HORIZON-TMA-MSCA-PF-EF - HORIZON TMA MSCA Postdoctoral Fellowships - European Fellowships

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Call for proposal

Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.

(opens in new window) HORIZON-MSCA-2024-PF-01

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Coordinator

INSTITUTO DE ENGENHARIA MECANICA
Net EU contribution

Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.

€ 191 343,12
Address
AVENIDA ROVISCO PAIS 1 INSTITUTO SUPERIOR TECNICO
1049-001 Lisboa
Portugal

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Total cost

The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.

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