Tool selection for five-axis curvature matched machining

This paper presents an automatic cutting tool selection methodology for five-axis finish surface machining based on the techniques of curvature matched machining. The criterion for cutter selection is to minimize the machine errors and to maximize material removal rate using an optimal filleted end mill selected from a standard cutting tool library. Tool parameters investigated include cutter radius, cutter corner radius and cutter length. The maximum swept silhouette of the inclined tool is proposed and implemented as tool radii selection protocols for matching the change in surface curvature. Algorithms for detection and correction of local tool gouging and global tool interference are presented. The local distance between the cutter bottom and the surface is used to detect and correct local tool gouging. Global tool interference detection and correction is solved by studying the shortest distance between the part surface and the cutter body axis. A faceted approach is used to accelerate the distance calculations. The solution to the local and global gouging problems leads to the shortest, most rigid, tool in the library. These methods of automatic tool selection have been implemented in ROBLINE using the C-language on the system. ROBLINE is a precursor to CODE (Cimetrix Open Development Environment) which is a complete commercial off-line/on-line machine modeling, development and control package. Machined examples confirm the effectiveness of these methods.