Nowadays, when milling complex parts or curved surfaces, we encounter several problems that must be taken into account in the production process. There are various factors that affect the quality and accuracy of production. The main objective of this paper was to analyze the size of the effective tool diameter when machining a shaped surface with respect to the selected position, namely at the perpendicular position of the tool. At the same time, the distribution of the engagement area on the tool surface was evaluated by extracting the area content and volume data at the point of contact. The experiment was also intended to highlight the importance of the choice of finishing strategy in a CAM system. The results showed that the tool engagement size corresponded to the extracted data describing the area and volume size for each tool position with respect to the curvature of the surface. The negative deviations obtained by the scanning method were due to machining close to the tool centre, which was affected by the changing effective tool diameter.

Shaped surfaces are increasingly used in the field of mould making for casting or injection moulding, where future products include shapes with different curvatures. These are surfaces that form convex curves, concave curves, or a combination thereof. Given these machined surfaces, it is important to know the impact of the finishing strategies on these surfaces. This paper deals with the comparison of finishing milling strategies in the production of shaped surfaces and the analysis of different methods for the evaluation of surface topography, surface roughness and the evaluation of deviations. The material used for the experiments was AlCu4Mg aluminium alloy, and Constant Z, Spiral and Spiral circle strategies were chosen for the finishing strategies. The evaluation of surface topography and surface roughness was carried out at three different sample heights with respect to the tool contact with the machined surface. The results showed changes in the toolpaths due to the variation of the effective diameter of the tool cutter to the machined surface as well as the choice of strategy. To produce specimens with corresponding shapes in terms of topography, the Constant Z strategy was the most suitable, in which uniform toolpaths were obtained over the whole height of the sample.

Clinching is a manufacturing method of mechanical joining two or more materials without the use of heat or additional components. This process relies on high plastic deformation to create a secure bond. Clinching technology is widely used for joining various grades and thickness of materials. Especially in the automotive industry, clinching is an alternative to spot resistance welding. However, the load-bearing capacity of clinched joints is comparatively lower when compared to resistance spot welded joints. This research aimed to enhance the load-carrying capacity of clinched joints. Experimental tests were conducted on clinched joints with locally modified microstructures to optimize their placement within the joint. The microstructure distribution in the clinched joint region was analysed using light and scanning electron microscopy, as well as microhardness measurements. Two material grades, micro-alloyed steels HX420LAD+Z and dual-phase ferritic-martensitic steels HCT600X+Z, were tested. Each grade underwent five groups of ten samples, subject to identical experimental conditions of local heating by resistance spot welding (RSW) and clinching. The application of RSW to the clinched joint area resulted in increase of load-bearing capacity for both joined types of materials.