Mathematical modeling of a generic multi-profile form milling cutter

In order to machine multiple sculptured surfaces with reduced machining time and high accuracy of the machined parts, shape design of a customised multi-point rotary cutting tool needs to be evolved. In the present work, a novel design of a generic multi-profile form milling cutter is developed for machining various multiple sculptured surfaces. This article describes in detail the mathematical model to design an accurate three-dimensional geometry of a generic multi-profile form milling cutter. Use of non-uniform rational B-spline curve(s) and sweep surfaces enables to control the shape of cutting flutes of the generic multi-profile form milling cutter. The article also discusses the methodology to develop a variety of cutters lying in the same conceptual family of multi-profile form milling cutter. To physically visualise the cutter and to show one of the downstream applications once a three-dimensional model of the cutter is available, one of the multi-profile form milling cutters is fabricated. The proposed methodology offers an intuitive high-quality mathematical model for a generic family of multi-profile form milling cutters, which is different from the traditional three-dimensional models.