Abstract: Methods, systems, and devices for designing and manufacturing flank millable components. In one embodiment, devices, systems, and methods for designing a flank millable component are provided, in which a user is notified when a component geometry option is selected that will result in the component not being flank millable. In another embodiment, the user is prevented from selecting a geometry option that would result in the component not being flank millable. In yet another embodiment, devices, systems, and methods are provided for manufacturing a component with a flank milling process, in which optimized machine instructions are determined that minimize milling machine motion.

Abstract: A method for determining machining instructions for flank milling of a workpiece which reduces the undercut by analyzing the cutter orientation at a plurality of orientations to determine an orientation which results in a minimum undercut, smooths the machining instructions by analyzing the movement of the cutter and the workpiece in spherical coordinates and improves machinability by analyzing for near-axial conditions and selecting a modified cutter orientation for such near-axial conditions using a multi-criteria weighting factor.

Abstract: A method for determining a smooth machining course for a cutting tool during machining of a workpiece. Each possible cutting tool position, with respect to the workpiece, is defined by a separate reference vector. A progression of points are defined as a tool path. A first specified portion of the reference vector will follow the tool path during machining of the workpiece. A series of reference planes are generated, each plane defines a planar set of all possible reference vector positions for each point. An acceptable range from eahc set is established which defines acceptable reference vector positions within each plane for each point. A tool course is generated, which will be followed by a second portion, distant from the first portion, of the reference vector utilizing an algorithm to minimize irregularities of the course, and to contain the course entirely within the acceptable range.