What is it?
Taper Barrel milling is ever growing in popularity. Traditionally, complex geometry with a double curvature such IML features on aerostructure surfaces would have been generated or scanned using ballnose cutters. This would significantly increase the overall cycle time due to the small step overs or step downs used to achieve the required surface finish or scallop height. Another application where these tools can be used is in very deep pockets where traditional endmills or long edge cutters struggle due to the instability invoked when using high length to diameter ratio tool assemblies.
A typical representation is shown above . The barrel radius is so large it is almost invisible to the eye.
The sketch below demonstrates how the taper barrel tool offers a much larger engagement area than the traditional ballnose and therefore allows an increased step down.
It also demonstrates how by tilting the tool away from the surface a shorter tool can be used if a 5-axis machine is available.
CATIA V5 and DELMIA 3DEXPERIENCE
Tapered Barrel tools are supported for multi axis machining in both CATIA V5 and 3DEXPERIENCE. Whilst both offerings support the function, 3DEXPERIENCE has some added enhancements such as the ability to add a washout radius to the cutting tool where the barrel radius meets the tool shank and the Barrel Angle making a much more user-friendly flow, shown in the image below.
The short video clip shows full 5 axis motion using the ‘Multi Axis Flank Contouring’ Manufacturing Operation within CATIA V5. The toolpath calculation respects the given tangency point allowing a larger stepdown whilst maintaining a good surface finish.
DTE Manufacturing Consultants
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