Grind-free tool path generation for five-axis surface machining

This paper discusses automatic tool path generation for five-axis filleted end mill finish-surface machining. A new method of automatic five-axis tool path generation is introduced called Grind-Free (GF) tool path generation. GF surfaces result from tool paths that avoid gouging and have scallops that are within the surface profile or waviness tolerances. New algorithms are presented for determining tool forward step and tool path step-over that produce a GF surface. Gouge-free tool paths can be generated directly from CAD data based solely on local and global machining constraints. The proposed methodology for GF tool path generation has been implemented in the C language using the CODE/Robline system. Surfaces were machined on a Boston Digital 505 five-axis milling machine to confirm this method.