An algorithm for precise machining area computation in rough machining of complex 3D pocket

The layer-by-layer machining approach is extensively used in both pocket and surface roughing process. Traditionally, the machining area is bounded by the intersecting curve of the part model and slicing plane. However, for the complex 3D pocket composed of inclined faces and groove feature, part of the area may be inaccessible for the cutting tool, resulting in interferences in the rough machining process. To tackle the problem, a novel algorithm that can avoid interferences is proposed. In this method, some basic terms such as static machining area (SMA), fringe edge (FE), and area side property (ASP) are described at first. The SMA can be generated through splitting the original machining area by the projection lines of FEs. Based on the ASP, the projection lines and original boundaries can be divided into two types: boundary line (BL) and non-BL. The boundaries of SMA can be constructed by linking BLs based on the accessibility analysis method. At last, two case studies are given to verify the feasibility and effectiveness of the proposed approach. The results show that the proposed algorithm can eliminate the interferences in the machining process.