NC tool path generation for 5-axis machining of free formed surfaces

This paper presents a 'tool axis vector' approach for machining sculptured surfaces. Such an approach is well suited for highly twisted, rolled, or bent surfaces. The tool paths are generated for a 5-axis milling machine. The proposed approach is based oil tilt angle, cutting direction, and a vector normal to the cutting surface. Gouging is avoided by checking the interference between the cutting tool and the part surface. The algorithm also finds maximum path intervals that generate maximum admissible cusp height within the specified tolerance limits. Such an approach minimizes the tool path and machining time. The paper presents an example to illustrate the details of the algorithm.