Cutter partition-based tool orientation optimization for gouge avoidance in five-axis machining

This paper presents a cutter partition-based tool orientation optimization algorithm that can identify and eliminate both local and rear gouging in five-axis machining. This algorithm is developed to generate smooth gouge-free tool paths for arbitrary free-form surfaces machined by general Automatically Programmed Tools (APT) cutters. The algorithm involves an iterative process of cutter projection to compute the gouge-free cutter positions. During each iteration, the cutter partition method is used to classify the cutting portion of the cutter, which in turn determines the gouging condition. Based on the classification, the algorithm applies an optimal gouge-avoidance strategy to minimize the size of tool orientation and position changes. The proposed algorithm can handle the combination of local and rear gouging (either separately or simultaneously), guarantee front edge cutting (avoiding damage to the cutter and surface), ensure a safety clearance between the rear edge of the cutter and the machined surface, and achieve minimal interruption to tool orientation and position from gouge avoidance. Simulation and cutting experiments confirm the effectiveness of the proposed algorithm.

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