Interference-free toolpath generation using enveloping element for five-axis machining of spatial cam

This paper presents an interference-free toolpath generating method for five-axis machining of a spatial cam. The notion of the proposed method is that the cutting tool is confined within the meshing element and the motion of the cutting tool follows the meshing element so that collision problem can be avoided. Based on the envelope theory, homogeneous coordinate transformation and differential geometry, the cutter location using the conical end mill is derived and the cutting path sequences with the minimum lead in and lead out are planned. Curvatures of the cam surface and the cutting tool are evaluated to offer the criterion for interference checking. To ensure the machining accuracy, the scallop height is used as a basis for generating appropriate toolpaths. The cutting simulations with solid model are performed to verify the proposed toolpath generation method. The proposed methodology can be used to automate the programming of tool paths for five-axis machining of spatial cam.