Algorithm for Determining the Optimal Cutter and Shank Length for Fixed 5-Axis Machining

Abstract

Dies and molds with very deep shapes are often fabricated using a fixed 5-axis milling machine. In the process planning of such machining, determination of the cutter and shank length is a time consuming task. In this paper, an algorithm for automatically determining the optimal cutter and shank length for fixed 5-axis milling operation is proposed. The optimal length can be derived by comparing a Minkowski sum object of the workpiece and the inverted zero-length cutter, and another Minkowski sum object of the part shape and the inverted cutter. These computations of Minkowski sum objects can be accelerated by using the depth buffer mechanism of GPU which is now installed on most PCs. An experimental system is implemented and some computational experiments are performed. Our system can determine the optimal cutter and shank length for milling a complex mold in a minute.