Planning the Coordinate Measurements of a Freeform Surface after Milling based on a CAD Model Simulating the Surface after Machining

Abstract This paper proposes the planning of coordinate measurements of freeform surfaces based on a model simulating the surface after machining. This model is created by the determination of a theoretical tool deflection during machining. The determined components of the simulated machining deviations are used in the reconstruction of the nominal CAD model of the surface into a model simulating the geometry of the surface after machining. This model is subdivided into areas corresponding to the assumed machining deviation intervals. This makes it possible to control the number and distribution of measuring points in separate sections of the manufactured surface. Coordinate measurements of the machined surface are made in areas where maximum deviations are expected. Here, the number and distribution of measuring points are controlled over a wide range. Coordinate measurements in other areas are carried out with significantly fewer points or may be omitted altogether. This approach makes it possible to reduce the measurement time without losing important information affecting the evaluation result. The method proposed in this paper has been tested on samples containing freeform surface. The test object was manufactured using a 3-axis milling technique with a spherical end mill.