Numerically Controlled Machining of Sculptured Surfaces

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The goal of this research is to increase the current knowledge base in the field of numerically controlled (NC) machining of sculptured surfaces. This research applies geometric simulation methods to three and five axis sculptured surface tool path generation. Specifically, the following questions are being explored: (1) What are the best algorithms for subdivision of sculptured surfaces into a polygonal representation to be used for NC tool path generation? (2) What is the time/accuracy trade-off in using points versus polygons as a surface representation for NC tool path generation? (3) Can the non-isoparametric tool path planning algorithm developed for three axis machining be extended to the five axis case? (4) Can efficient and accurate geometric models of the volume swept by a five axis tool movement be defined? (5) Can parallel algorithms be applied to the NC tool path planning problem? This project is an interdisciplinary collaboration between the Mechanical Engineering Department at the University of New Hampshire, the Department of Mathematics and Computer Science at Dartmouth College, and an industrial sponsor. It has the potential of greatly improving sculptured surface machining. In practice, it should enhance the production of metal forming dies.