Direct 5-axis tool posture local collision-free area generation for point clouds

Abstract

This paper presents a method of tool posture local collision-free area generation for 5-axis machining point clouds. Considering it is time-consuming and complicated to calculate the entire precise area, in this paper, discrete inclination angles are obtained in its available range, and the precise collision-free rotation angle ranges of each inclination angle are calculated to construct the collision-free area in 2-dimensional configuration space (C-space). In local gouging avoidance, an algorithm is presented to calculate the maximum equivalent tool radius with the local contour line of the point cloud near the cutter contact (CC) point, which defines the local gouging-free ranges of rotation angles and discrete inclination angles. In rear gouging avoidance, if the tool rotates by some specific angles, a rear gouging point will be outside the tool and the gouging is avoided. Based on the way, an algorithm is presented to calculate the gouging-free ranges for discrete inclination angles. Finally, the intersections of local and rear gouging-free rotation angle ranges define the collision-free area. This presented method applies to flat-end milling cutter and torus milling cutter, and two examples are given to illustrate the feasibility.