Automatic tool path generation for multi-axis machining

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1998.Includes bibliographical references (leaves 67-72).We present a novel approach to CAD/CAM integration for multi-axis machining. Instead of redefining the workpiece in terms of machining features, we generate tool paths directly by analyzing the accessibility of the surface of the part. This eliminates the problem of feature extraction. We envision this as the core strategy of a new direct and seamless CAD/ CAM system. We perform the accessibility analysis in two stages. First, we triangulate the surface of the workpiece and perform a visibility analysis from a discrete set of orientations arranged on the Gaussian Sphere. This analysis is performed in object space to ensure reliability. For each triangle, a discrete set approximation of the accessibility cone is then constructed. Next, a minimum set cover algorithm like the Quine-McCluskey Algorithm is used to select the minimum set of orientations from which the entire workpiece can be accessed. These set of orientations correspond to the setups in the machining plan, and also dictate the orientation in which the designed part will be embedded in the stock. In particular, we bias the search for setups in favor of directions from which most of the part can be accessed i.e, the parallel and perpendicular directions of the faces in the workpiece. For each setup, we select a set of tools for optimal removal of material. Our tool-path generation strategy is based on two general steps: global roughing and facebased finishing. In global roughing, we represent the workpiece and stock in a voxelized format. We perform a waterline analysis and slice the stock into material removal slabs. In each slab, we generate zig-zag tool paths for removing bulk of the material. After gross material removal in global roughing, we finish the faces of the component in face-based finishing. Here, instead of assembling faces into features, we generate tool paths directly and independently for each face. The accessibility cones are used to help ensure interference- free cuts. After the tool paths have been generated, we optimize the plan to ensure that commonalities between adjacent faces are exploited.by Laxmiprasad Putta.S.M