An efficient analytical model for the swept volume generation of a flat-end mill in 5-axis CNC milling

5-axis CNC (Computer Numerical Control) milling is widely used to create complex part geometries in the industrial area. The cutting tool creates the swept volume as it moves along the defined path. The swept volume is subtracted from the initial stock for the machining simulation. Although a swept volume consists of three parts such as ingress, egress, and swept envelope, the number of faces of the swept volume is higher than three. In this work, parametric equations of the faces of the swept volume were obtained for a flat-end mill in four steps. The model is based on the decomposition of the tool into circles along the tool orientation vector since a flat-end mill can be modeled as a cylinder. The fundamental principle is that each circle is tangent to the swept envelope of the cylinder. Locations of the grazing points with respect to a local coordinate system were determined by applying the Envelope Theory to the parameterized circle of the cylinder. Then, each face of the swept volume was represented based on the equation of the parameterized circle. The model was verified by using an alternative analytical model. As a result, boundaries of the swept volume were represented fully analytically for a flat-end mill in 5-axis CNC milling in an efficient way.