Efficient Cutter-Freeform Surfaces Projection Method for Five-Axis Tool Path Computation.

The complex surfaces are usually approximated as Z-maps, point based models or facet models to simplify the computation for cutter positions. However, such surface approximation error may result in the conflict between the accuracy of cutter positions and the computational efficiency, and C1 discontinuity for tool paths and tool orientations. In this paper, an efficient cutter-freeform surfaces projection (CFSP) method based on the cutter-facet model projection (CFMP) method is proposed for five-axis tool path computation to solve the above issues. Motivated by the Newton-Raphson algorithm, the tangent plane-based search method is developed to find the accurate cutter contact points on surfaces. The golden section-based search algorithm is further carried out to deal with the convergence oscillation problem. Simulation on the part models validates that the algorithm is effective to improve the machining accuracy.