Novel Tool Path Generation Method for Pocket Machining Using Sound Field Synthesis Theory

Abstract

Contour parallel tool paths have been proved to be a preferred machining strategy for their advantage of less tool retractions and less sharp turns. The traditional geometrical algorithm-based tool path generation method often makes it hard to simply and simultaneously solve the problems of self-intersection, no residual, and smoothness at the same time due to their contradictions. To address this issue, a contoured parallel tool path generation method for pocket machining is developed in this study. It is based on sound field synthesis theory inspired by the phenomenon of sound wave propagation. Firstly, the simplified medial axis (SMA) tree of the pocket is extracted and the propagation direction of each SMA segment is calculated on account of the geometric characteristics of the pocket boundary. Secondly, the final tool path is obtained through the synthesis of the sound field. Finally, the novel method is verified on five different pockets to generate a contoured parallel milling tool path. After machining these pockets and measuring the machining time, roughness, and cutting force, the experimental results demonstrate that the tool path obtained by the novel method has advantages in improving machining quality and efficiency.