Abstract
Abstract
A method for three-axis machining of sculptured surfaces with optimal workpiece orientations (set-ups) is presented. The procedure consists of two steps: accessibility analysis and clustering of points to be machined. Feasible tool orientations along which the tool can reach the cutting locations (CLs) without colliding with the workpiece are first determined using point accessibility analysis. The cutting locations are then classified into separate groups according to their accessibility domains in order to define the workpiece set-ups. Finally, the CL points are sorted out in each group to generate tool paths. The part surface is, therefore, virtually divided into a set of subareas, and each subarea is separately machined with a defined part set-up. The main objective is to minimize the number of part set-ups, to increase the number of feasible tool orientations in each set-up and to decrease tool path discontinuity. This makes it feasible and economical to utilize three-axis machines with a table with two degrees of freedom for cutting five-axis machinable sculptured surfaces. The primary application of the introduced algorithm is in machining processes, where it can efficiently determine optimal tool orientations in surface finishing. The solution is suitable for many other manufacturing applications, such as inspection, assembly, robotics, painting and welding. Two examples including a complex centrifugal pump are used for verification.