Global optimization of tool path for five-axis flank milling with a cylindrical cutter

In this paper, optimum positioning of cylindrical cutter for five-axis flank milling of non-developable ruled surface is addressed from the perspective of surface approximation. Based on the developed. interchangeability principle, global optimization of the five-axis tool path is modeled as approximation of the tool envelope surface to the data points on the design surface following the minimum zone criterion recommended by ANSI and ISO standards for tolerance evaluation. By using the signed point-to-surface distance function, tool path plannings for semi-finish and finish millings are formulated as two constrained optimization problems in a unified framework. Based on the second order Taylor approximation of the distance function, a sequential approximation algorithm along with a hierarchical algorithmic structure is developed for the optimization. Numerical examples are presented to confirm the validity of the proposed approach. Supported by the National Natural Science Foundation of China (Grant Nos. 50775147 and 50835004), the National Basic Research Program of China (“973” Project) (Grant No. 2005CB724103), and the Science & Technology Commission of Shanghai Municipality (Grant No. 07JC14028)