CNC Tool Path Asymmetry for Minimizing Surface Marks
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Solution Overview
Problem
Conventional CNC machining techniques result in undesirable tool marks and require extensive machine time for producing complex, finely detailed reliefs, limiting the creation of representative designs due to the need for small router bits and numerous passes, which leads to visible grooves and peaks.
Innovation Solution
The method involves creating non-parallel tool paths that follow curving lines to minimize tool marks, allowing for efficient carving of complex forms by manipulating the tool paths to produce a natural-looking surface texture that hides or emphasizes tool marks as a decorative element, thereby reducing the appearance of machine-made imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small router bits are used with numerous passes to create finely detailed reliefs, then manufacturing precision is improved, but productivity deteriorates due to excessive machine time
Solution Approach 1:
The patent applies asymmetry by using non-uniform spacing between tool paths, where the distance between adjacent passes varies along the carving path. This asymmetric spacing creates overlapping cut regions that eliminate tool marks without requiring uniformly small step-over distances, thereby reducing total passes while maintaining fine detail quality
Solution Approach 2:
The patent implements dynamics by making the tool path spacing variable rather than fixed. The spacing between tool paths is dynamically adjusted along the carving path, with closer spacing in regions requiring finer detail and wider spacing where less detail is needed, optimizing both precision and productivity
2Manufacturing precision
If small router bits with numerous passes are used, then manufacturing precision is improved, but device complexity increases due to multiple tool changes and path configurations
Solution Approach 1:
The patent applies local quality by varying the tool path spacing locally along different sections of the carving path. Rather than using a uniform spacing throughout, the system adjusts spacing based on local requirements for detail quality, allowing coarser spacing in less critical areas and finer spacing only where needed, thereby reducing overall complexity
3Ease of manufacture
If conventional parallel tool paths are used, then ease of manufacture is improved, but object-generated harmful factors worsen due to visible tool marks and machine-made appearance
Solution Approach 1:
The patent eliminates the harmful parallel tool marks by replacing symmetric parallel paths with asymmetric non-parallel paths. The varying spacing and angles of adjacent tool paths prevent the formation of uniform grooves and peaks, thereby hiding tool marks while maintaining manufacturing simplicity
Solution Approach 2:
The patent converts the potentially harmful effect of tool marks into a beneficial overlapping cut pattern. By spacing tool paths to overlap rather than just touch, the previously harmful grooves and peaks are eliminated, and the overlapping regions create smooth transitions that enhance surface quality
Data Source
AI summary
A method for preparing tool paths for use in a computer numerically controlled machine whereby the appearance of undesirable horizontal tool marks are minimized, comprised of identifying a surface texture and resolving the surface texture into at least one contour and identifying an underlying relief. A tool path is then prepared which is suitable for use in a computer numerically controlled machine wherein the tool path moves in accordance with the at least one contour of the identified surface texture while simultaneously carving the underlying relief.