An integrated approach towards process planning for 5-axis milling of sculptured surfaces based on cutter accessibility map

Abstract

In 5-axis milling (finish cut) of sculptured surfaces, the cutter's accessibility to the part surface is an important issue for subsequent process planning tasks. In this paper, a unique algorithm is presented to evaluate the accessibility of a cylindrical fillet-ended cutter to a point on the part surface by considering machine axis limit, avoidance of local-gouging, rear-gouging, and globalcollision. By applying this algorithm to the sampled points of a given part surface, the accessibility map (A-map) of the cutter to any point on the part surface can be obtained. More significantly, the A-maps can be subsequently employed for optimal cutter selection, optimal cutting direction selection, and optimal tool-path generation. It is expected that by employing this concept, the process planning tasks for 5-axis milling of sculptured surfaces can be carried out in an integrated and efficient manner.