5-axis tool path generation with collision detection for finish machining of freeform surfaces

Research in the field of Tool path generation for freeform surfaces has been done intensively in the past. However, the main challenge that still exists is the computational efficiency related to the tool path generation. Tool path generation for freeform surface involves instantaneous calculation of new tool orientations which does not collide with the neighboring surfaces. Since the collision check of tool and neighboring surface is done repetitively at every instant of the tool, the calculations at every instant are to be computationally as easy as possible. This thesis is composed of one paper. Paper I presents a novel extension of the Bounding Box technique used for collision detection. This novel method solves the above mentioned challenge of computational efficiency in the field of tool path generation. The new approach that has been implemented in Paper I involves using the simplest computational operators that are comparison operators along with a novel Diagonal Bounding Box technique. This ensures the tool path generation to be less cumbersome computationally. Furthermore, the boundaries of the proposed machining algorithm in terms of collision correction and the proper application of the machining algorithm have been explored --Abstract, page iv

Uncertainty Analysis in Laser Deposition Finish Machining Operations

The Laser Aided Manufacturing Process (LAMP) from Missouri S&T is a laser based metals rapid manufacturing process that uses machining to improve the final part\u27s surface finish. When free-form machining, the absence of enough deposited material results in inconsistent scallop heights which result in poor surface finish or incorrect geometry in the final part. This paper investigates a probabilistic approach to various uncertainties involved in the deposition and subsequent machining of an arbitrary part. Furthermore, this paper analyses the machine errors which makes the response of Scallop Height to exceed the predefined maximum scallop height when traveling along the tool path interval distance. Tackling these problems allows us to achieve the final part shape with higher accuracy