Tool path planning for 5-axis flank milling based on dynamic programming techniques

This paper proposes a novel computation method for tool path planning in 5-axis flank milling of ruled surfaces. This method converts the path planning (a geometry problem) into a curve matching task (a mathematical programming problem). Discrete dynamic programming techniques are applied to obtain the optimal matching with machining error as the objective function. Each matching line corresponds to a cutter location and the tool orientation at the location. An approximating method based on z-buffer is developed for a quick estimation of the error. A set of parameters is allowed to vary in the optimization, thus generating the optimal tool paths in different conditions. They reveal useful insights into design of the tool motion pattern with respect to the surface geometry. The simulation result of machining different surfaces validates the proposed method. This work provides an effective systematic approach to precise error control in 5-axis flank milling. © 2008 Springer-Verlag Berlin Heidelberg.