Abstract
This paper presents a robust method to decompose a sculptured surface into convex and non-convex regions with specific range of curvature. This method provides important tools for tool path generation and cutter size selection for NC machining of sculptured surfaces. Convex regions can be machined efficiently with a large ball-end cutter. Non-convex regions can be milled using a smaller ball-end cutter to avoid gouging. The tool paths are the intersection curves between parallel planes and the sculptured surface. The values of the step length and the path interval are calculated based on the machining tolerance requirements. After detecting and eliminating the tool interference, the interference-free tool path is generated. The effectiveness of the developed algorithm is demonstrated through simulation and actual cutting tests.
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