Interference detection and optimal tool selection in 3-axis NC machining of free-form surfaces

This paper presents a systematic tool-path generation methodology which inc orporates interference detection and optimal tool selection for machining f ree-form surfaces on 3-axis CNC machines using ball-end cutters. In this me thod, the global and local interference is first detected and prevented, an d then the optimal tools in terms of machining time are selected and tool p aths are generated. A system of five algorithms is developed to determine t he interference area. On the basis of these algorithms, the machining time of each available tool is estimated by considering tool size, scallop heigh t, and accessible surface area. Finally, the combination of tools which pos sesses the minimum overall machining time is selected as the optimal tool s izes. Our case study has demonstrated the validity of the proposed methodol ogy and algorithms. (C) 1999 Elsevier Science Ltd. All rights reserved.