Selecting optimal set of tool sequences for machining of multiple pockets

In computer-aided manufacturing domain, the selection of cutters significantly affects the machining time. However, it is difficult for humans to determine the optimal or near-optimal set of cutting tools, in particular for complex parts with multiple features. Traditionally, every feature is machined one-by-one, and no cutter sharing is taken into consideration. To perform machining operations efficiently, both the number and size of cutters should be selected carefully. Therefore, this paper proposes a new approach to determine optimal cutting tool sequences for machining multiple features in a single setup, which has been implemented and integrated with a feature-based process planning system for the generation of a numeric control code. To seek a general approach to compute the coverable area of each cutter for machining arbitrary region shapes in the case of multiple cutters combination, a new algorithm is introduced by improving the scan line-based polygon filling algorithm. To do so, the features with the nonpolygon profiles have to be approximated as polygons according to the requirement of the tolerance. The proposed method has been verified by experiments.

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