Tool Path Generation for High-quality Automatic Finish Machining

Abstract This paper proposes a new method for tool path generation. The method calculates tool paths efficiently and accurately by geometrically tracing or integrating a differential equation for intersection between offset surfaces of a product and constraining planes of a tool. It can avoid cutter interference with a product for a surface part having a smaller curvature radius than a cutter radius as well as a concave part for several surfaces and a convex edge. The tool path keeps an outer part of the object by finding an inflection curve which divides convex and concave surface parts. Applying the method to finish electrical discharge machining (EDM) with planetary motion in powder suspended fluid, accurate mirror-like surfaces of a product or a die have been obtained without manual cusp removal works.