Int J Adv Manuf Technol (2007) 34:1072–1087

DOI 10.1007/s00170-006-0680-6

ORIGINAL ARTICLE

Geometry design model of a precise form-milling cutter

based on the machining characteristics
Ger Chwang Wang & Kuang Hwa Fuh & Biing Hwa Yan

Received: 24 November 2005 / Accepted: 7 May 2006 / Published online: 12 December 2006
# Springer-Verlag London Limited 2006

Abstract This paper presents a new approach to design a Lc grinding parameter of the flute (mm)
form milling cutter for precisely obtaining the complex free- χ helix angle (degree)
form surfaces. In this study, the intersection point of the rake PO cutter-tip
surface, helix flute and clearance flank is appropriately PN intersection point of rake surface, helix flute
defined due to its significant role in the design and grinding and clearance flank (or intersection point
performance. The angle-solid-block analysis is developed to between cutting and side cutting edge)
establish the new cutter geometry model. Hence, a new form- Pi the i-th charactheristic point (intersection point)
milling cutter satisfying the requirements of machining between the i-th and i+1-th Hermite curve,
characteristics of workpiece can be designed. In addition, where i=1∼N-1
the cutter geometric model can be adopted to map out the h absolute z-coordinate value of PN (mm)
measuring strategy with minimum measured points to attain CP characteristic point
the exact geometric feature of cutter. Nedge amount of cutting edges
Nmeasure amount of measured characteristic point
Keywords N-segments cutting edges . Angle-solid model . α1 longitudinal clearance angle of cutting edge on
Angle-solid-block . Always normal . the first clearance flank (degree)
Geometry characteristic . Characteristic points . α2 longitudinal clearance angle on the second
Computer-aided inspection clearance flank (degree)
α longitudinal clearance angle of cutting edge on
Abbreviations the first clearance flank (cross-sectioned by
D cutter diameter (mm) z=-h plane) (degree)
w design parameter of flank (mm) α0 true angle of α
α3 clearance angle on the second clearance flank
Submitted to: The International Journal of Advanced Manufacturing (cross-sectioned by z=-h plane) (degree)
Technology. This paper has not been published nor has it been α30 true angle of α3
submitted for publication elsewhere. γ rake angle of cutting edge measured on x=0
G. C. Wang : B. H. Yan (*) plane (degree)
Department of Mechanical Engineering, γS side rake angle of cutting edge measured on
National Central University, z=-h plane (degree)
Wuchang Li,
Chung Li, Taiwan 32054, Republic of China
γ′ rake angle of cutting edge measured on side
e-mail: bhyen@cc.ncu.edu.tw view from rake surface (degree)
β grinding parameter (degree)
K. H. Fuh τ grinding parameter, τ−90° is the draft angle for
Department of Mechanical and Mechatronic Engineering,
National Taiwan Ocean University,
the grinding of rake surface (degree)
5 Peiling Road, ρ grinding parameter (degree)
Kee Lung, Taiwan 20224, Republic of China θNC1 adjutant design parameter (degree)
Int J Adv Manuf Technol (2007) 34:1072–1087
RNC1 adjutant design parameter (mm)
XYZ global coordinate system
XMYMZM coordinate system for inspection
XProfYProf local coordinate system of cutter profile
XgYgZg local coordinate system for grinding the flank
1 Introduction
1.1 Motive of research
A multifacet drill (MFD) with multifacet and multiflanks
has been distinguished from its significant characteristics
such as lower cutting forces, better heat transfer, more
accuracy, longer tool life, higher productivity, etc [1]. A
three-axis milling machine with a ball-nosed milling cutter
is the familiar method in the free form surface milling
process. However, its precision has less refinement than a
five-axis milling machine with an end mill. In every milling
location, the coincidence between tool axis and surface
normal for five-axis milling process has better performance
than three-axis process. If the coincidence between tool axis
and surface normal is identical, it is referred to as being
always normal; the term “quasi-normal” is proposed to
describe the relative normal degree. In this case, the
consideration of milling characteristics and application to
multi-axis degree of freedom has to be taken into account to
help design a ball-nosed milling cutter with multifacet and
multiflanks. Accordingly, it leads to better geometric
precision and geometric compatibility of workpieces, and
this milling cutter is called a form milling cutter in this
study. Therefore, a geometric design model for precise form
milling cutter is the main purpose of this study.
This study probes into the modeling research of cutting
edge geometry to drive off the problems of surface normal
vectors, which are different from point to point based on the
concepts of always normal and quasi-normal. Accordingly,
the inspection method is developed to verify the theory and
performance of modeling.
1.2 Review
In order to exactly solve the above problems, both the
cutter and workpiece’s geometric characteristics have to be
verified and unified at first. Glaeser, Wallner and Pottmann
[2] made a concept definition for workpiece characteristics,
but the corresponding cutter characteristics have not been
well defined. The method of always normal (named as axis
milling by Baptista and Simoes [3]), proposes that the
spindle is normal to the free-form surface on the cutting
point in the workpiece. Baptista and Simoes showed some
larger scallops were left and then replaced the ball-nosed
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end mill by an end mill inclined in the feeding direction to
reduce the scallop dimension. However, it was not suitable
for 3-axis milling.
Lee and Chang [4] used the 2-phase approach with 4-th
and 5-th axis postures to avoid the global cutter interfer-
ence caused by the cutter and its holder. A method by
Yoon et al. [5], presented locally optimal cutting positions
for cutting directions on the 5-axis sculptured surface
machining. The cutter positions can guarantee local
gouging avoidance. Both [4] and [5] briefly described
the limitation of cutter posture in the 3-axis milling
processes. Glaeser [2] offered an idea on selecting a cutter
of collision-free 3-axis milling for free-form surfaces, but
the cutter design has never been studied. Regarding the
suitable tool-path of 3-axis milling on free-form surface,
Park and Choi [6] described a direction-parallel method
and Park [7, 8] proposed both characteristic contour and
z-map methods. Nevertheless, the geometric relationship
between the cutting edge and the workpiece was not fully
described.
Tsai and Wu [9] showed the quadratic surface flanks for
drill point design and grinding. Fujii et al. [10] defined the
cutting edge of drill geometry as wire frame algorithm. Wu
and Shen [1] derived the configuration of the multifacet
drill. All of the above cutter geometric models were
analyzed by the analytic geometry method. Then, Wang et
al. [11] investigated the geometry of a multifacet drill with
a new approach - the angle-solid-blocks method. This study
analyzed the relationship of the geometry of the drill-tip,
flanks and straight cutting edges and then found the
relationships of the cutting parameters, which depend upon
one another. However, the approach [11] has not yet
developed the angles-relation of the cutter geometry for
the generation of curved cutting edges, multi-segments
edges and flutes. So a new modeling method for the form
milling cutter is still required.
Bradley and Chan [12] used reverse engineering in the
inspection of a ground cutter with a touch probe and laser
scanning. But they still lacked the better method for
measuring the geometry of cutting edge.
1.3 Guidance of research
The intersection of rake surface, helix flute and clearance
flank is defined as PN and also the connected point of the
cutting edge and side cutting edge. It plays an important
role in the design and grinding of the milling cutter. The
first step of the research is to define the nominal
relationship of the cutting tool as shown in Fig. 1. The
correlation between PN and the adjoining cutter geometry
has to be taken precisely into account, otherwise it results in
inaccurate geometry for grinding due to the parameters
interference mentioned by Wang et al. [11]. Therefore, PN
1074
Fig. 1 The defined characteristic points along the cutting edge of a
precise form-milling cutter
is taken as the prerequisite key point for the following
designing, grinding and measuring methods.
One of the key terms of the precise milling is that form
accuracy can be improved if the cutter point on the cutting
path is kept as normal to the cutting surfaceas possible.
If any cutting position of the cutter allows the workpiece
to be quasi-normal in the 3-axis machining process, then
some strategies need to be studied. The 4-th axis inclination
has an important effect on the geometry of the cutter
projection-profile so that the manner of 4-th axis is
incorporated directly into the cutter design. For improving
the cutter precision of 3-axis precise milling, it is attempted
to impose both 4-th and 5-th axes’ movement degrees of
freedom and the relative characteristics on the cutter’s
geometric design.
An inspection method verifies the geometric quality of
the cutter with the measured characteristic points through
reverse engineering. Additionally, the angular-solid ap-
proach [11] for proving the relationships among the cutter’s
design parameters is required. Then it has been realized that
once the minimum of measured characteristic points have
been defined, where the accuracy of the design parameters
of N-segments-edge form the milling cutter, can be verified
by the re-modeling process of reverse engineering.
A new approach is developed in this work based on the
specification of machining characteristics. In this research,
some workpiece’s geometries are taken as practice machin-
ing characteristics. A precise form milling cutter’s CAD
solid geometry model is designed according to the
geometrical characteristics as described above. The cutter
geometric models are then constructed by the rapid
prototype (RP) method called 3D printing. Finally, the
accuracy is verified by the least amount of measured
characteristic points satisfying the requirement and fitting in
the relationship among design parameters. Hereby, a cutter
Int J Adv Manuf Technol (2007) 34:1072–1087
with more complicated features is designed, based on the
research so that the geometry’s reliability is advanced
concretely and feasibly.
Furthermore, for the total solution oriented objects, there
must be an effective approach to develop a model for
design, grinding and inspection.
2 Normal algorithm
Based on the machining characteristics of the workpiece,
the major normal vector interval is defined, and a multi-
segment cutting edge by the utilization of few characteristic
points, such as a threshold point or control point in the
interval, is accordingly designed. The characteristic point
has to be always normal and regarded as the basis
information for forming the cutting edge, according to the
adoption of this study. However, the projection-profile of
each adjoining characteristic point has to fit in with the
condition of quasi-normal and becomes the major issue of
this section.
2.1 Classification of always normal
2.1.1 Hermite curve
Faux and Pratt [13] demonstrated the advantage of
piecewise Hermite interpolation to easily get the first-
derivative continuity without causing severe oscillation
problems. They also mentioned the main disadvantage that
the gradient values is hard to find. While in this paper, each
characteristic point can actually define the normal condition
on the 2D (two dimensional) projection-profile of the cutter
and the tangent vector which is perpendicular to the normal
vector.
2.1.2 Arc
The arc, similar to Hermite curve, also has the first-
derivative continuity, but it causes a severe oscillation
problem. Its main advantage is suitable for defining the
multi-arc edge milling cutter [14]. The normal vector is
derived by linking the arc center to the target cutting point.
2.2 General equations available for quasi normal
2.2.1 Brief expressions of projection-profile and cutting
edge
The milling cutter can be formed by grinding or turning as
a revolved-body [15]. Then, flutes, rake surfaces, clearance
surfaces and the other surfaces of the cutter are ground
sequentially. The continuous projection-profile of the
Int J Adv Manuf Technol (2007) 34:1072–1087
cutting edge is divided into some segments as piecewise
continuously in the next step - called N-segments edge. The
definition of N-segments edge profile is shown in Fig. 2 - a
2D half projection-profile of cutter in XProf, YProf coordi-
nate system (local coordinate system). The more N-seg-
ments, the larger the database of cutter model, and the
better the accuracy of the geometry.
2.2.2 Quasi normal for the cutter geometry
with N-segments edge
The general design model can be derived from the
relationship between the cutter design parameters and the
projection-profile of N-segments edge. The fundamental
geometry of the N-segments edge described in Fig. 2 can be
illustrated in the form of Ferguson’s parametric cubic
curves.
Each segment of cutting edge can be expressed as
[13, 16]:



rðt Þ ¼ rð0Þ 2t 3  3t 2 þ 1 þ rð1Þ 2t 3 þ 3t 2



þ rð0Þ t 3  2t 2 þ t þ rð1Þ t 3  t 2 ð1Þ
Fig. 2 Definition of the half projection-profile in the x-y profile
coordinate system (local coordinate system). n: normal vector.
Pprof i: characteristic point i on half projection profile
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with
rð0Þ ¼ α0 T ð0Þ; rð1Þ ¼ α1 T ð1Þ;
where T(0), T(1) are the unit tangent vectors at the two ends
of each segment. Faux and Pratt [13] suggested that the
sizes of α0 and α1 do not exceed by triple times of the
chord length L ¼ jrð1Þ  rð0Þj:
3 The geometry characteristics of both workpiece
and cutter
To choose or design a suitable cutter by both analyzing and
surveying the geometric characteristic of the workpiece is
much more beneficial for precisely milling the free-form
surfaces.
3.1 Definition of the geometrical characteristics
between workpiece and cutter
There are some assessments and definitions obtained by the
following procedures. By studying on the definition for the
geometry characteristics of workpiece, a proper shape of
cutting edge will be developed for promoting the precision in
3-axis milling up to the 4-axis or 5-axis milling has, and the
cutting edge will be designed as properly piecewise division.
For a case the 3-axis milling on free-form surfaces,
Fig. 3a shows the existing method without the spindle tilt
axis. Regarding the conditions in Fig. 3a, it is necessary to
define as a milling characteristic for designing a proper
cutter. For a cutter without the traditional concept, as shown
in Fig. 3b, its projection-profile can be determined by
scaling up or down from the workpiece’s projection-
profiles, which are suitable in the finish milling.
3.2 Main approach of designing the high-accuracy form
milling cutter
3.2.1 Definition of the characteristic points of cutter
projection-profile
The sketch map in Fig. 4 shows the position on the cutting
location of the 3-axis milling with normal vectors of
workpiece and cutter. This is an improved type z-constant
contour machining from the methods of Park [7, 8]. By this
machining approach, a suitable projection-profile of cutter
is regarded as the design goal.
The basic position-calibration points including the cutter
tip (coordinate origin) and the point PN, and the character-
istic points on the projection-profile of the cutter, greatly
influence the cutting efficiency. The normal vectors or
tangent vectors are defined on the cutter’s characteristic
points.
1076 Int J Adv Manuf Technol (2007) 34:1072–1087

Fig. 3 Schematic illustration of

the 3-axis milling on the free-
form surface: (a) the existing
method; (b) the cutter projec-
tion-profiles designed based on
the characteristics of workpiece
geometry

3.2.2 Projection-profile of cutter mapped by the workpiece’s system. From the numerical method and the assumption of
characteristic points dx≈0, the 2D coordinate of the characteristic point on
projection-profile has a general form of (x, z(x)). The point
A significant goal of this research is dedicated to satisfying (x+dx, z(x+dx)) is near to the characteristic point at the
the requirements - the least characteristic points of cutter designed Hermite curve. The derivative is set as x′=dx,
and the minimum workpiece’s geometry error. An available z0 ¼ zðx þ dxÞ  zð xÞ. Therefore, the tangent vector on the
mathematical model is herein developed for finding the i-th characteristic point is
interval coordinate value between any two neighbouring 0 0
characteristic points. And also be applicable for verifying : xi : zi
xi ðt Þ ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
02 02
ffi  L; zi ðt Þ ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
02 0
ffiL ð2Þ
the inspection stratagem. xi þ z i xi þ zi2
The characteristic points of the workpiece can be
mapped to the 2D projection-profile of cutter. For always
where, L is the average chord length among the three
normal, any two adjacent characteristic points will be
characteristic points ðxi1 ; zi1 Þ; ðxi ; zi Þ; ðxiþ1 ; ziþ1 Þ, as
linked by a Hermite curve.
given by
3.2.3 Determination of tangent vector on the characteristic qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1
point L¼ ðxi  xi1 Þ2 þ ðzi  zi1 Þ2 þ ðxiþ1  xi Þ2 þ ðziþ1  zi Þ2
2

The projection-profile of cutter is expressed as a piecewise

continuous type of Hermit curves in the x-z 2D coordinate
Fig. 4 Modified z-constant
contour machining
Int J Adv Manuf Technol (2007) 34:1072–1087 1077

Substituting Eq. (2) into the general Eq. (1) yields a

simplified 2D projection-profile, and the tangent vectors of
the two ends of a Hermite curve are obtained as xi−1 =xi(0),
zi−1 =zi(0), xi =xi(1), zi =zi(1).
As mentioned above, the equations of the N-segments
Hermite projection-profile are necessary for precisely
designing a quasi-normal form-milling cutter. Therefore,
the definitions are extremely important in the processes of
designing, grinding, inspection and tool path simulation.

4 Angle-solid-blocks method developed for cutting

parameters of the cutter model

The mathematical expressions of critical and representative

angle-solid-blocks are developed, and briefly introduces in
following sections.

4.1 Relations of design parameters analyzed by angle-solid-

blocks method Fig. 5 Spherical angle-solid-block including the rake surface

4.1.1 Rake surface angle-solid-block based on point PN, is created to extablish

Firstly, a revolved solid model has been created by a half
projection-profile revolving about the cutter axis. The
controlled terms consisting of two key points, O(0,0,0)
and PN(-D/2,0,-h), and the tilt vector from point PN with γ
are located on the surface of the revolved solid model. The
revolved solid model is then sliced by the controlled terms
and formed a new angle-solid-block as shown in Fig. 5. For
the given values of D, h, the relationship between side rake
angle γS and rake angle γ from the angle-solid-block can
be established in order to furtherly develop the functional
relationship γS=f(D, h, γ) or γ=f(D, h, γS). Therefore, γ
can be considered as a standard design parameter that is
related to γS.
 
2h tan γ
γS ¼ Tan1 ð3Þ
D new joined-model rotates γS angle clockwise about z-axis,
The rake surface (taken as reference plane) is derived in
the following equation.
D D
h tan γ x þ y þ tan γ z ¼ 0 ð4Þ
2 2
Equation (4) can be used to transform the characteristic
points on the 2D projection-profile for mapping the same
amount of new characteristic points on the 3D cutting edge.
the relationship between side clearance angle α and its true
angle α0, as given by
tan α
α0 ¼ Tan1 ð5Þ
cos γ
where α can be directly measured. The angle α0, design
parameter, can be calculated according to Eq. (5) for
constructing an easy-ground model.
4.2 Angle-solid-block for inspection and positioning
For the goals of inspection and positioning, an angle-solid-
block OPNO1Q is developed to illustrate the relationships
among γ, γ′, D, h and γS as shown in Fig. 6a. The angle-
solid-block OPNO1Q is joined to the cutter’s CAD solid
model by the calibration of the characteristic point PN. The
and then rotates γ′ angle counter clockwise about ZM-axis
of the new coordinate system XMYMZM as a inspection
gesture, as shown in Fig. 7. According to the angle-solid-
block, an equation can be derived. The angle γ′ is suitably
calculated from the given design parameters D, h, γ as
following equation.
D  tan γ
γ0 ¼ Tan1 pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð6Þ
D2 þ 4h2 tan2 γ

4.1.2 Clearance surface Alternatively, Eq. (6) can be replaced by the form
γ=f(D, γ′, h) and h=f(D, γ′, γ), or can be developed as
A horizontal position of side clearance surface located near h=f(D, γs, γ) from Eq. (3). All available equations can be
the point PN is available for clearance angle inspection. An derived by the analysis of the angle-solid-block method. It
1078 Int J Adv Manuf Technol (2007) 34:1072–1087

Fig. 6 (a) The angle-solid-

block OO1PNQ illustrating the
relationship of γ and γ′, and the
plane OPNQ is an askew plane.
(b) Rotating the angle-solid-
block OO1PNQ by –γs about
Z-axis. (c) Rotating the angle-
solid-block O′O′1P′N Q′ by −γ′
about X-axis. The plane
O″P″N Q″ is on the orthogonal
plane y=0

is shown that these parameters used in the above equation path, must be able to be calculated only by the 2D
depend on one another. projection-profile definition. Therefore, a series of program-
ming processes needs to be developed.

5 Design processes and computer-aided modeling 5.1 Cutting edge geometry

of cutter geometry
The flow chart, as shown in the left part of Fig. 8, illustrates
the continuous processes from the projection-profile defi-
nition of the cutter to the NC path decision for grinding the
clearance surfaces. It is less easy for searching the gradient
values of 3D Hermite curves. The gradient values of the
Hermite curves, including 3D cutting edge and NC grinding
For describing the accuracy of the cutting edge, the
coordinate value needs to be obtained from any position
of the cutting edge. From the given characteristic point
Pi(xi, 0, zi) of the projection-profile, a relationship mapped
on the cutting edge for developing characteristic point
Qi(Xi, Yi, Zi) is expressed in the following equations:
D D
h tan γ Xi þ Yi þ tan γ Zi ¼ 0 ð7Þ
2 2

Zi ¼ z i ð8Þ

Xi2 þ Yi2 ¼ x2i ð9Þ

From Eqs. (7–9), Qi(Xi, Yi, Zi) is determined as given by

pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
b  b2  4a  c
Xi ¼ ;
2a ð10Þ
2h tan γ
Yi ¼ Xi  tan γ Zi
D

where

Fig. 7 Combination of angle-solid-block OPNO1Q and tool solid

D2 þ 4h2 tan2 γ 4hzi tan2 γ
model for performing coordinate transformation into a inspection a¼ ; b ¼ ; c ¼ z2i tan2 γ  xi2
gesture D2 D
Int J Adv Manuf Technol (2007) 34:1072–1087
Fig. 8 Flow chart of the design
processes and the geometry
construction
Based on the developed equations of projection-profile
and rake surface (Eq. (4)), it is possible to derive the
Hermite equations of the cutting edge.
A more close neighboring point approaching to Qi on
the cutting edge is defined as Q′i(Q′ix, Q′iy, Q′iz), and the
tangent vector of the i-th characteristic point is expressed as
 
Xi  Q0ix Yi  Q0iy Zi  Q0iz
L; L; L ð11Þ
dL dL dL
where dL is the length of Qi Q0i and L ¼ Qi Qiþ1 is chord
length.
Accordingly, the coordinate values and tangent vectors,
described by Eq. (11), of the two adjacent characteristic
points are substituded into the general Eq. (1) of Hermite
curve. The geometry equations of the piecewise continuous
cutting edge can be derived exactly and piecewisely.
5.2 Grinding path for cutting edge with quasi normal
The matrix form is suitable for representing the coordinate
transformation. The relationships between different forms
of coordinate systems XYZ (globe) and XgYgZg (grinding),
need to be developed. The coordinate systems XgYgZg is the
same as XMYMZM shown in Fig. 7. Thus, the key matrix M
1079
is the product of two coordinate transformation matrixes,
RZ (−γS) and RX (−γ′).
M ¼ RZ ðγS Þ  RX ðγ0 Þ ð12Þ
2 3
cos ðγS Þ sin ðγS Þ 0
RZ ðγS Þ ¼ 4  sin ðγS Þ cos ðγS Þ 0 5;
0 0 1
2 3
1 0 0
RX ðγ0 Þ ¼ 4 0 cos ðγ0 Þ sin ðγ0 Þ 5
0  sin ðγ Þ cos ðγ0 Þ
0
The transformation matrixes are useful in the jug-
calibration process for grinding the clearance surfaces.
The askew plane OPNQ on the angle-solid-block
OO1PN Q, as shown in Fig. 6a, can be set for being
coincident with orthogonal plane y=0 after the angle-solid-
block OO1PNQ is rotated twice. The angle-solid-block
O′O′1P′N Q′, as shown in Fig. 6b, is obtained by rotating
the angle-solid-block OO1PNQ an angle −γS about Z-axis.
The angle-solid-block O″O″1P″N Q″, as shown in Fig. 6c, is
obtained by rotating the angle-solid-block O′O′1P′N Q′ an
angle −γ′ about X-axis. In the Fig. 6c, the Y-coordinate
values of point P″N and Q″ are equal to zero.
1080
From the above verification illustrated in Fig. 6, any
point or vector (e.g., a characteristic point and tangent
vector on cutting edge) on the rake surface can be
transformed to locate on the plane y=0 according to
Eq. (12). Therefore, a group of new 2D Hermite curves
(y=0) for NC grinding paths of clearance surfaces can be
successfully designed.
5.3 Computer-aided modeling
The flow chart, as shown in the right part of Fig. 8, shows
the feature-based solid modeling processes, taking into the
grinding sequence of the cutter. The main processes
including the grinding sequence are described as follows.
5.3.1 Parameters selection
The cutter design parameters, as shown in a template of
Fig. 9, are classified into external and internal parameters.
1. External parameters for constructing N-segments
cutting edge
A N-segments cutter, consisting of characteristic points
(P0(x0, z0), P1(x1, z1), P2(x2, z2),........,PN,(xN, zN)) and
normal vectors and diameter D, is similar to the main
projection-profile as shown in Fig. 2.
Fig. 9 Geometry parameters of a quasi-normal form-milling cutter with four characteristic points (N=3)
Int J Adv Manuf Technol (2007) 34:1072–1087
2. Internal geometry parameters
The parameters are classified as design and grinding
parameters (as shown in the local left part of Fig. 9) for
constructing various features of cutter model.
5.3.2 Angle-solid-blocks for computer-aided modeling
Because the internal parameters cannot be straightly
measured, the internal parameters for CAD modeling need
to be obtained by using the angle-solid-blocks approach.
1. Angle-solid-block of rake surface
The tetrahedron body OO″ PNQ is shown in Fig. 5.
2. Angle-solid-block of flute
The cross section profile of the flute on plane z=−h is
defined based on the rake surface. Figure 10a shows the
angle-solid-block of flute. The grinding parameter τ
(contain DD1PN angle DD1P2 of plane and) as a function
of γ, LC,γs D, β, β0 can be determined from the angle-
solid-block.
3. Angle-solid-block of clearance surface
The angle-solid-block based on the point PN, as shown
in Fig. 10b, presents the relationship between the clearance
angle α0 (for computer-aided modeling) and the measured-
clearance angle α.
Int J Adv Manuf Technol (2007) 34:1072–1087 1081

Fig. 10 Analysis diagram of

angle-solid-blocks for creating
primitives of the cutter model:
(a) construction of the flute
angle-solid-block based on the
rake surface, the triangle
PND1D2 is recommanded for
creating a basic cross-section of
flute; (b) angle-solid-block for
creating side clearance angle

Fig. 11 CAD solid model

obtained by the subtraction op-
eration: (a) half projection-pro-
file and rough model; (b) rake
surface; (c) flute and side clear-
ance surface; (d) first and sec-
ond clearance surfaces, some
modified surfaces, and fillet
surfaces
1082 Int J Adv Manuf Technol (2007) 34:1072–1087

5.3.3 Boolean operation

The processes are similar to those defined by Wang et al.

[11]. The modeling processes of the cutter model with the
subtracting operation as shown in Fig. 11 are performed
through modeling a cutter solid by constructing as shown
from Fig. 11a–d.

6 Verification

A group of rapid prototypes, printed by a 3D printer, are

verified from the designing processes to the measuring
processes.

6.1 Rules for verification

For designing the form-milling cutter, the accuracy of the

geometries can be verified by utilizing the approach of
angle-solid model to search the correlation among primary
design parameters. An error of the dependent parameter in
the correlation will cause some errors of primary param-
eters. Similarly, a change in the independent the parameter
does not influence the other parameters. On the other hand,
the amount of measured characteristic points Nmeasure
in practical inspection is related to the amount of cutting
edge Nedge by Nmeasure≥Nedge+2. For a two-edges cutter Fig. 12 The CAD cutter model based on the geometry characteristics
(Nedge=2), the suitable value of Nmeasure is set to be greater of workpiece
than 4. These measured points consist of the origin, the two
PN points on the edges, and some proper points selected
from one edge. The reasonable error range is mainly dependent on the
The characteristic points and cutting edges (the main requirement.
terms in verification) are likely to be overground in the
process of grinding the clearance surfaces. Three standard 6.2 Verification processes of virtual model
rules for the verification requirement are described as
follows. A computer simulation is necessary before performing
practical inspection. The verification processes are impor-
1. The coordinate system of measured points is trans-
tant for an accurate simulation.
formed to be coincident with the globe coordinate
system. Then, both the measured coordinate value PN
6.2.1 Cutter of workpiece’s geometry characteristics
and cutter diameter would be within the suitable range
compared with the design values.
A design case is based on the geometry characteristics of
2. Any measured characteristic point detached on the
the workpiece as shown in Fig. 3. The CAD solid model of
cutting edge needs to be near the Hermite curve which
the cutter for precise milling is shown in Fig. 12. The z-axis
is constructed by two adjacent design characteristic
of the cutter model is set to be the initial standard entity for
points.
calibration in the inspection processes. The model in
3. The design parameters γ and γS must be satisfied with
Fig. 12 is an example showing the design and inspection
the defined relationship.
parameters obtained by the CAD solid model. According to
Otherwise, all the calculation errors are expressed as the simulation processes, the outside diameter is
follows. 19.932 mm, and the design parameters related to cutting
edge are:
Measure value  Design value
Error ¼ % ð13Þ
Design value α1 ¼ 14:60 ; γ ¼ 18:00 ; χ ¼ 18:00 ; γS ¼ 18:10
 Table 1.
grinding
β ¼ 67:70 ; β0 ¼ 45:00
the grinding parameters are:

grinding path obtained as 2D coordinate values

Int J Adv Manuf Technol (2007) 34:1072–1087

τ ¼ 1:86 ; α2 ¼ 20:60 ; LC ¼ 1:50mm; ρ ¼ 95:00 ;

6.2.2 Geometry accuracy of cutting edge due to Hermite

inspection simulation. The grinding gesture of the cutter

2D coordinate (xg, yg) by a matrix MT. The key matrix MT is

(in global coordinate system) is obtained by multiplying the

the tool; (b) points (t=0, 0.5, or 1) on every Hermite curve of the
RX(γ′) and Rz(γS). The coordinate on the cutting edge
the product of two coordinate transformation matrixes,
Hermite grinding for different conditions are listed in
model is shown in Fig. 13b. The coordinate values of
the projection-profile with eight characteristic points as

In the table, the coordinate on the cutting edge (xE, yE, zE)

Fig. 13 (a) Characteristic points on the design projection-profile of

shown in Fig. 12, is evaluated by the computer-aided
The verification for grinding the Hermite edge, produced by

Table 1 Coordinate values and geometry errors in Hermite grinding (unit: mm)

Row Characteristic point P0 P1 P2 P3 P4 P5 P6 P7(PN)

t value 0 0.5 1, 0 0.5 1, 0 0.5 1, 0 0.5 1, 0 0.5 1, 0 0.5 1 1

1 2D Characteristic point of x 0 −3.093 −5.817 −7.413 −9.010 −9.488 −9.966 −9.966

projection profile z 0 −0.740 −2.393 −3.701 −5.585 −6.415 −7.370 −10.000
2 2D coordinate value on the xg 0 −1.582 −3.085 −4.473 −5.770 −6.580 −7.325 −8.167 −8.844 −9.094 −9.279 −9.504 −9.703 −9.4752
Hermite grinding path yg 0 −0.215 −0.775 −1.567 −2.505 −3.152 −3.874 −4.796 −5.845 −6.263 −6.714 −7.208 −7.713 −10.466
3 3D coordinate value on cutting xE 0 −1.524 −3.004 −4.396 −5.715 −6.545 −7.318 −8.204 −8.943 −9.219 −9.436 −9.695 −9.930 −9.966
edge by multiplying Row 2 yE 0 −0.430 −0.739 −0.947 −1.086 −1.155 −1.183 −1.186 −1.101 −1.061 −0.992 −0.923 −0.843 0
the matrix M T ¼ Rx ðγ0 Þ  Rz ðγS Þ zE 0 −0.205 −0.740 −1.497 −2.393 −3.011 −3.701 −4.583 −5.585 −5.984 −6.415 −6.887 −7.370 −10.000
4 3D Theorem coordinate value on x 0 −3.004 −5.715 −7.318 −8.943 −9.436 −9.930
the cutting edge by using Eq. (12) y 0 −0.739 −1.086 −1.183 −1.101 −0.992 −0.843
to transform 2D value of Row 1 z 0 −0.740 −2.393 −3.701 −5.585 −6.415 −7.370
5 Hermite cutting edge by Eq. (1) xH 0 −1.524 −3.004 −4.396 −5.715 −6.545 −7.318 −8.204 −8.943 −9.219 −9.436 −9.695 −9.930
yH 0 −0.430 −0.739 −0.947 −1.086 −1.155 −1.183 −1.186 −1.101 −1.061 −0.992 −0.923 −0.843
zH 0 −0.205 −0.740 −1.497 −2.393 −3.011 −3.701 −4.583 −5.585 −5.984 −6.415 −6.887 −7.370
1083
1084 Int J Adv Manuf Technol (2007) 34:1072–1087

(xH, yH, zH) (in global coordinate system) is obtained by

general Eq. (1). The coordinates on the mid-position of
each Hermite edge at t=0.5 are in agreement with each
other for the same value of a Hermite edge.

6.2.3 Errors in spline curves based on Hermite curves

(only the 2D projection-profile)

The spline curves of the CAD package (AutoDESK MDT

Version 2004) are used to simulate the Hermite curves of
the projection-profile for reducing the database of cutter
geometry. A case with maximum error 0.08% for the
projection-profile of rough model determined by the CAD
model is shown in Fig. 13a. Therefore, the Hermite curve
can be precisely simulated by the spline curve for
computer-aided modeling. It is noted that a cutter model
is successfully constructed using the spline curves for
simulating Hermite edge.

6.3 Verification from design to inspection

Verification procedures from design to inspection is
comprised of: (1) The computer virtual solid model, named
as Piece 0, whose geometry errors are approaching to zero
in the computer-aided measuring processes. (2) For RPs are
named as Piece 1 and 2. In the RP manufacturing processes
performed by the 3D printer, a number of geometry errors
are generated because of glue solidification and gravity
deformation. According to the data obtained from Piece 0,
the errors in the results of piece 1 and 2 can be estimated.
Both Piece 1 and Piece 2 in Fig. 14 (workpieces of RP)
are scaled down to 0.5 and 0.3, respectively, based on the
identical CAD solid model as shown in Fig. 12.
The assigned positions of the measured characteristic
points for Piece 0 are shown in Fig. 15a. The measured
poses of Piece 1 and 2 are almost not orthogonal. The
measured probe data (see Table 2) in order to be restored to
the CAD model scale and the coordinates system of RPs are
transformed to the same one of the cutter design model.
Then, the measuring errors are derived by the approach of
CAD/CAM and reverse engineering. The steps satisfying
three standard rules are described in Appendix B.
In review of the printing processes of RP, Piece 1 was
printed in the transverse gesture (z-axis horizontal). Piece 2
was vertical (z-axis up). The geometric errors of Piece 1
were obviously generated with the gravity-effect deforma-
tion in the printing processes. The errors of Piece 2 mainly
result from the improper glue painting in the post-
processes, so that the cutter axis is deformed into tilt type.
Because the maximum error of probe Eprobe in the
measuring processes for cutting edge is about less than
0.5 mm, Eprobe≪D. Therefore, the value of the Eprobe on the
cutting edge is much less than the errors of RP deformation.
Fig. 14 RP models with different scales based on the solid model of
Fig. 12
6.4 Verification conclusion
The errors of CAD model Piece 0 are almost equal to zero.
The errors of RP model Piece 2 are relatively large
according to the rule 1. Therefore, the piece 2 is judged
as defect one. The errors of RP model Piece 1 are due to the
deformation effect of gravity. However, Piece 1 is still
available for the next verification step, rules 2 and 3. The
Piece 1 is the better one in quality based on the survey for
measured data of Piece 1 and 2.
7 Conclusions
1. The unified geometry model is developed for the
design, grinding and inspection of form-milling
cutters. The model potentially satisfies the specifica-
tions of the geometric characteristics for various free-
form surfaces.
2. For precision, each geometric checkpoint (PN) for
designing, grinding and measuring cutters needs to be
set on the same point. In addition, the rake surface
should include the primary characteristic point PN.
3. Adding the 4-th and 5-th machining axis into the cutter
design strategy can improve the accuracy. The accuracy
achieved in the cutter of 3-axis machining adapting this
design strategy is higher than that of the conventional
cutters.
Int J Adv Manuf Technol (2007) 34:1072–1087 1085

Fig. 15 The schematic defini-

tion of the measured points and
the characteristic points of CAD
model Piece 0A: (a) CAD mod-
el and virtual measured points;
(b) probe data transformed on
the CAD model for verification
by rule 1; (c) characteristic
points added to CAD model for
verification by rule 2

4. The geometries of cutting edges derived by the
piecewise continuous Hermite equations may fulfill
the goal for constructing a cutter model.
5. This research enables the cutting edges of existing
cutters to be precisely reconstructed, using the method
of reverse engineering. Based on a few characteristic
points and the derivative values, the cutting edge of the
existing cutter can be measured.
6. A derived unified model in the present study reveals
that the projection-profile of the cutter can be more
precisely obtained from the correct key parameters γ,
γS, h. This model is very useful for the quality
1086 Int J Adv Manuf Technol (2007) 34:1072–1087

Table 2 Errors of measured characteristic points (CPs) based on the rule 1 (measurement standards are near the root of cutter; Pb Prob; unit, mm)

Sample Measured CPs Reference point of

spindle; cutter
Origin (P0) PN1 PN2 PN3 diameter

0 (CAD solid model M1 (0, 0, 0) M2 (−9.966, 0.000, M3 (4.948, M4 (4.983, 8.631, MO (0, 0,
in Fig. 12) −10.00) −8.651, −10.000) −43.500)
−10.000) 19.9323
1
Scaled 0.2 to model Pb1 (0, 0, 0) Pb2 (−10.113, Pb3 (5.145, Pb4 (4.078, 9.020, (0, 0,
in Fig. 12 0.000, −8.145, −9.900) −36.581)
−10.026) −9.881) 20.157
Shift error Calibration 0.747 0.527 0.953
point
2
Scaled 0.3333 to Pb1 (0, 0, 0) Pb2 (−8.920, 0.00, Pb3 (5.929, Pb4 (4.983, 8.631, (0, 0,
model in Fig. 12 −9.548) −9.123, −10.000) −34.959)
−10.415) 19.929
Shift error Calibration 1.140 1.144 1.086
point

management of the form milling cutter as well as the
other tools.
7. The 3-axis form milling cutter is designed by the
proposed method incorporating the cutting behavior of
4-th axis. Accordingly, it can reduce the indentation
effects caused by the dead point of the cutter.
8. More importantly, the coordinate values of any point on
the cutting edge can be obtained in the present study,
being very useful for developing the force model.
Appendix A
Finding measured angle 2γ′
For calibrating a cutter to be measured to the orthogonal
point is necessary. For measuring a two-cutting-edges
cutter, at least six characteristic points P1, P2, P3, P′1, P′2,
P′3 are needed.
The coordinates of are P1, P2, P3 are (x1, y1, z1), (x2, y2,
z2), (x3, y3, z3).
The coordinates of are P′1, P′2, P′3 are (x′1, y′1, z′1), (x′2, y′2,
z′2), (x′3, y′3, z′3).
The contain angle 2γ′ between P1, P2, P3 plane and P′1,
P′2, P′3 is obtained by the analytical geometry method.
ðl1 l2 þ m1 m2 þ n1 n2 Þ
2γ0 ¼ Cos1 pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffipffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð14Þ
l1 þ m21 þ n21 l22 þ m22 þ n22
2

position the same as the CAD model, more than one PN

Table 3 Errors of measured characteristic points (CPs) on the rule 2 (reverse engineering by calibration based on PNS, unit: mm)

Workpiece with less Measured CPs Two design characteristic points on the cutting edge near the Error%*
error according to rule 1 measured characteristic point. (design characteristic points):
[tangent vectors]

Piece 1 (scaled 0.2 to Virtual M5 P2E(−5.715,−1.086,−2.393):[−2.118,−0.185,−1.555] 0.0005/

model in Fig. 12) (−5.800,−1.093, 6.393=0.01%
−2.456)
P3E(−7.319,−1.183,−3.702):[−1.670,−0.041,−1.552]
Probe 3 (−4.320, P1E(−3.003,−0.739,−0.740):[−2.857,−0.502,−1.321] 0.132/
−0.840,−1.345) 4.602=2.86%
P2E(−5.715,−1.086,−2.393):[−2.118,−0.185,−1.555]
Probe 4 (−7.913, P3E(−7.319,−1.183,−3.702):[−1.670,−0.041,−1.552] 0.039/
−1.214,−4.291) 9.083=0.43%
P4E(−8.943,−1.101,−5.585):[−0.948,0.158,−1.438]

*••(Distance between the measured point and the nearest location at Hermite curve) / (Distance between measured point and origin)**
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
**••For the case of Prob3: Distance between the measured point and the origin is DPr ob3 ¼ 2
XPr ob3 þ YPr ob3 þ ZPr ob3
2 2
Int J Adv Manuf Technol (2007) 34:1072–1087 1087

Table 4 The calculated parameters according to equations and the rule 3 (the same calibration as the rule 2, unit: mm or degree)

Workpiece with less error Data type h γ′(deg) d γ(deg) γS(deg)

according to the rule 1

Piece 1 Design value 10.000 17.17 19.932 18.00 18.06

Calculating by reverse 10.000 17.42 19.932 18.30 18.36
engineering pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Equation |PNz| Eq. (14) 2 PN x2 þ PN y2 Eq. (6) type Eq. (3)

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