Machining of free-form solids using an octree volume decomposition approach

Objects with free-form shapes have typically been created as surface models. While the finishing tool path can be generated using the surface definition, there are still gaps between the final surface and the intermediate process planning steps. The common process planning information such as the sizes of rough cut tools, rough cut paths, intermediate shapes, and machined volumes cannot be determined based solely on the surface definition. To accomplish the link, one approach is to model the free-form shape as a solid model to obtain the volumetric process planning information. In this research, a free-form solid is defined as a solid with free-form surfaces as the boundary. To generate the information required for process planning, the free-form solid can be approximated with a set of cubic blocks in organized sizes using octree decomposition. The intersecting property between the free-form solid and the subdivided cubic blocks is used to determine further subdivisions. The subdivision proceeds until the...