The sweep plane algorithm for global collision detection with workpiece geometry update for five-axis NC machining

A new algorithm based on the sweep plane approach for global collision detection for five-axis NC machining is presented. This algorithm takes into account not only collisions between the tool and workpiece, but also collisions between the other parts of the CNC machine, especially the change of the workpiece geometry is included in the detection process. The workpiece and machine bodies are firstly approximated by an octree of bounding spheres. Collision detection is conducted between these spheres. If there is any interference between these bounding spheres, their subspheres are further tested. The subdivision process is recursively performed until the resolution reaches the desired precision level. If there is no interference between the spheres, there is no need to subdivide any more. When the interference is detected between the spheres in the last octree level, the slices within these colliding spheres are further checked by using the sweep plane algorithm to determine whether the enclosed objects really collide with each other. In the sweep plane algorithm, most of the slices of the moving bodies stay parallel and their collisions are detected by checking the interference between these parallel slices using 2D polygon clipping. Whereas, if the slices are not parallel to the reference slicing direction (due to the rotary axes), the interference detection is conducted by examining overlaps of the projections of these slices on the three perpendicular planes XY, YZ, and ZX. The accuracy of the algorithm can be adjusted by changing the distance between the sweep planes. The algorithm can be applied to any five-axis CNC machines. (C) 2007 Elsevier Ltd. All rights reserved.