FREEFORM SURFACE REGION OPTIMIZATION FOR 3-AXIS AND 5-AXIS MILLING

A regional optimization of automatically generated machining toolpaths for computer based freeform mechanical models is considered in the fr amework of multiaxis (3-5) machining operations. A trichotomy of an ar bitrary freeform shaped surface into convex, concave and saddle-like r egions is considered. Saddle-like and concave regions can be milled us ing a ball end tool, in 3-axis or 5-axis mode. A subset of the convex regions can be machined faster and with a smaller scallop using a flat end tool that is aligned with the normal of the surface in 5-axis mod e. A method to robustly detect and eliminate local gouging of the mill ing tool into the object is developed and demonstrated on an actual pa rt.