Multiple-axis sculptured surface machining

Abstract

This paper presents swept envelope techniques to generate optimal tool paths for multiple-axis sculptured surface machining. The properties of the swept envelopes are analysed. The results help us to realise the geometric matching in tool-tip machining and understand the geometric machinability in tool-side machining. The target surfaces are classified into open-boundary sculptured surfaces and closed-boundary pocket surfaces, based on the existence of the surrounding obstacles. The objective of the open-boundary sculptured surface machining is to maximise the machining strip width of the fillet-end tools for tool-tip machining and, thus, to optimise the machining efficiency. On the other hand, the goal of the closed-boundary pocket machining is to smooth the tool axes of the ball-end tools for both tool-tip and tool-side machining and, therefore, to optimise the tool path variation. The complement of the swept envelope, which represents the in-process workpiece, is also addressed. It finally demonstrates the developed techniques and illustrates the application examples.