Tools and methods are provided for scarfing rotor blade segments. A rotor blade segment includes a pressure side and a suction side. A tool includes a first guide configured for mounting on one of the pressure side or the suction side, the first guide including a first curved rail and a second curved rail spaced from the first curved rail. The tool further includes a second guide movably coupled to the first guide at a scarf angle, the second guide including a guide rail extending between and movable along the first curved rail and the second curved rail. The tool further includes a cutting device movably coupled to the second guide, the cutting device movable along the guide rail and operable to remove material from the one of the pressure side or the suction side.

Systems and method relating to machining parts include a CNC system including CNC machining tools, and a computer including a processor and a computer-readable medium, wherein the computer-readable medium encodes instructions of a single NC program that, when run on the processor, causes the computer to control a selected CNC machining tool to perform operations including alternating between (i) moving the selected CNC machining tool along a semi-finishing toolpath segment using a first set of spindle speed and feed rate values to remove a next portion of rough stock material in a next region of a part being manufactured, and (ii) moving the selected CNC machining tool along a finishing toolpath segment to remove a semi-finishing thickness portion of the part in the next region, wherein the first set of spindle speed and feed rate values are different from the second set of spindle speed and feed rate values.

A tool is disclosed that has an elongated tool body defining a longitudinal axis and includes a ball-end section having a positive taper angle relative to the longitudinal axis of the tool body, and a relief section that extends rearwardly from the ball-end section and has a negative taper angle relative to the positive taper angle of the ball-end section.

A multi-flute endmill including a cutting edge part having multiple cutting edges and flutes formed between adjacent cutting edges in a rotation direction around the tool axis O. A rake face of each cutting edge is formed from a rake face of an end cutting edge from the tool axis O side to the outer peripheral side of a shank, an adjacent rake face of a corner R edge that forms a surface different from the rake face of the end cutting edge, and an adjacent rake face of a peripheral cutting edge that forms a surface different from the rake face of the corner R edge. A gash is formed between the rake face of the end cutting edge and a flank of an end cutting edge that is adjacent on a forward side thereof in the rotation direction R.

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.