Optimal Tool Path Generation for 2½ D Milling of Dies and Molds

Sculptured parts are usually produced through 2 ½ D rough machining and 3D–5D finish machining. The 2 ½ D, or contour map, rough machining plays a major role in removing excess material of the stock to form the parts. Improvement of this process can significantly increase the productivity of die and mold manufacturing. In this work, a number of algorithms were introduced to reduce the machining time of 2 1/2 D roughing. These include a new representation of various cutting layers, a method of tool path generation and planning for parallel and stock-offset milling. A simulation example is used to demonstrate advantages of the new approach.