Experimental data from a three-axis dynamometer reveals an expected close correlation between instantaneous engagement and cutting force. Overall path lengths are shorter, and acceleration requirements (as dictated by path curvature) are greatly reduced. Simulations reveal far less variation in cutter engagement and near-constant material removal rates. A state-based algorithm is developed that formalizes these alternate strategies of path generation and controls the transitions between them.Ĭase studies are shown comparing these new tool path trajectories with conventional contour-parallel approaches. During periods in which constant engagement cannot be maintained, the path curvature and entry and exit angles are controlled explicitly. A smooth (C2) trajectory is generated, maintaining an ideal constant engagement state as much as possible. To address these problems, a new offset for tool path generation that maintains an ideal steady-state process by explicitly controlling the instantaneous engagement of the cutting tool is introduced.Ī generative spiral-in algorithm for 2 1 2 D material removal of convex geometries is presented that continuously monitors the state of the milling process, including cutter engagement, path curvature, and the instantaneous entry and exit angles. When the mechanics of the milling process are considered, widely varying cutter engagements and sharp velocity discontinuities are found to significantly limit the efficiency of these approaches. Contour-parallel and direction-parallel machining strategies have gained nearly universal acceptance for simple 2 1 2 D material removal tasks.

Constant engagement tool path software