The production of shape accurate forming dies in the toolmaking industry requires a high degree of manual labour. To achieve a higher level of automation, machine-based approaches are necessary. Therefore, robot-based milling experiments of difficult-to-machine cold work steel 1.2379 are carried out. This paper presents an experimental study of different path strategies using an industrial robot to mill example geometries of a forming die. Starting with preliminary tests to determine the best possible process and machining parameters, a conventional machining process strategy follows as a reference. Based on the findings two different strategies are derived: additional tool inclination and the avoidance of circular movements that are eventually joined and regarded in combination. Four different path strategies are carried out to determine the influence on form deviation in a CNC-like multi-step material removal process. Results are analysed and discussed regarding geometric fidelity and cutting moments of the example geometries.
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