Optimal cutter selection for complex three-axis NC mould machining

Proper cutter selection can reduce NC machining time greatly. Most researchers select cutters based on tool path generation, which is very time consuming, and only a very limited number of cutters can be selected. A new cutter selection methodology for complex mould machining based on an efficient interference detection algorithm is introduced. With this approach, the feasible regions for the candidate cutters are first identified without tool path generation. The machining times for different cutter combinations are then estimated based on the areas of the feasible regions and the cutter feed rates. The set of cutters that can machine the workpiece with minimum time is selected as the optimal candidate cutters. Since no tool path needs to be generated before cutter selection, the cutters can be selected efficiently, and the number of the cutters that can be used in NC machining can be quite large. The system has been tested with several industrial parts and it can select optimal cutters effectively and efficiently.