A global cutter positioning method for multi-axis machining of sculptured surfaces

Traditional cutter positioning methods have defects of global errors and incomplete optimization. Because of using local differential geometry and focusing on the cutting contact point, these defects cannot be avoided and will deteriorate accuracy in precision machining. The authors presented the conception of actual cutting edge of a toroidal mill which was extended from cutting contact point, and pointed out its importance in programming. Instantaneous cutter position error (ICPE) was also investigated. A new global method based on the ICPE curve was presented. Taking the relationship between surface and cutter into consideration thoroughly, this global method shows many advantages which have been verified by simulation and cutting tests. (C) 2005 Elsevier Ltd. All rights reserved.