Abstract
In current multi-axis CNC manufacture technology, the sculptured surface has to be approximated to simplify its complexity, therefore, the current machining methods can not fully exploit the flexibility of the multi-axis CNC tools and offer the prospect of higher machining efficiency and better machining quality. A new theory (Envelope-Approximation Theory) was presented to generate the sculptured surface by maximizing the machined strip width based on the moving frame. The differential geometry based on the idea of the moving frame was discussed to determine the related motion of the tool and the workpiece. The optimized model of the related motion of the tool was established to enable the envelope of the tool surface approximate to the predesigned surface aiming at the least warping. Simulated examples based on Matlab7.0 demonstrate the improved machining efficiency and precision of the Envelope-Approximation Theory over current published methods.
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