Enhancing machined surface quality through optimized CAD/CAM interpolations and tolerance adjustments

ABSTRACT The VP50 steel, characterized by its bainitic/martensitic microstructure, poses significant machining challenges, including elevated cutting forces and heat generation. These factors directly impact surface roughness, as hardened surfaces tend to exhibit greater irregularities when cutting parameters or tools are not properly optimized. The objective of this study is to critically analyze the quality of machined surfaces using CAD/CAM programming tools during the milling of VP50 steel cavities with spherical-tip carbide inserts. The analysis focuses on the influence of two types of interpolations (linear and circular) and tolerances (0.05 mm and 0.1 mm), which define the tool path during the machining of a three-dimensional cavity. Surface roughness and geometric accuracy were selected as the primary responses due to their crucial role in determining the functional performance and quality of machined components. These indicators are widely used in the literature as key metrics for evaluating the efficiency of machining strategies and the impact of CAD/CAM parameters on the final product quality. The results indicate that circular interpolation with a 0.1 mm tolerance is the most effective option for minimizing shape deviations and enhancing process accuracy.