Tool-path generation for five-axis machining of free-form surfaces based on accessibility analysis

Five-axis machining of free-form surfaces has one major advantage over three-axis machining, i.e. a greater degree of flexibility in positioning the cutting tool relative to the surface. In five-axis machining of free-form surfaces there are three major phases in creating the tool path: (i) generation of the cutter contact (CC) points; (ii) formation of the cutter location (CL) points that define the path followed by the cutting tool reference point; and (iii) the creation of the specific machine tool part program (G-code file). In this paper, the free-form surface is defined as a triangular polyhedral mesh. The CC-points are created from the surface mesh definition employing a cutting plane technique. Additionally, the CC points are positioned based on an examination of several important factors: geometric constraints derived from the machine tool axis limits, gouging (undercutting) of the free-form surface by the cutting tool and collision of the tool with either the machining stock or machine. The CL points can then be generated along the resulting CC points by consideration of specific machining strategies, such as cusp height and a smooth change in tool posture. The critical issues addressed in this work concern the avoidance of machining problems (machine limit, collision, and gouging) in the tool-path generation phase. Therefore, this technique avoids inefficient five-axis machining practices by automatically creating and verifying a feasible tool-path prior to the actual metal cutting.