CNC Tool Path Planning With Step-Up Cuts to Minimize Material Removal
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Solution Overview
Problem
Existing automated tool path design systems for computer-controlled machining do not effectively minimize material removal while ensuring that machined surfaces lie within specified limiting surfaces, leading to inefficiencies in the machining process.
Innovation Solution
A method for generating tool paths that involve multiple step-up cuts at varying heights along the Z-axis, with decisions on cutting locations and heights based on the required non-vertical slope of the finished object, to ensure surfaces are between inner and outer limiting surfaces, minimizing material removal and optimizing the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional automated tool path design systems are used, then machining can be performed, but material removal is not minimized and machined surfaces may not lie within specified limiting surfaces
Solution Approach 1:
The tool path is divided into multiple step-up cuts at different heights along the Z-axis. Each cut removes material at a specific height range, allowing precise control over the machined surface position. The segmentation of the machining process into discrete height levels enables the system to minimize material removal while ensuring surfaces lie within the inner and outer limiting surfaces.
Solution Approach 2:
The invention introduces height (Z-axis) as an additional dimension for controlling material removal. By varying the cut height across multiple levels, the system optimizes both precision and material efficiency. The offset surface and scallop surface definitions create a three-dimensional boundary framework that guides the tool path generation to achieve precise surface positioning while minimizing waste.
2Manufacturing precision
If multiple step-up cuts at multiple heights are implemented, then material removal is minimized and surface precision is improved, but the complexity of tool path calculation increases
Solution Approach 1:
The offset surface and scallop surface are pre-defined before tool path generation. These limiting surfaces establish the boundaries for all subsequent cutting operations. By preparing these geometric constraints in advance, the complex multi-height tool path calculation is simplified, as the algorithm only needs to operate within the pre-established boundaries rather than calculating them dynamically.
Solution Approach 2:
The tool path system dynamically adjusts cut heights and positions based on the workpiece geometry and limiting surfaces. The automated calculation adapts the number of step-up cuts and their specific heights to match the required precision while minimizing material removal. This dynamic optimization reduces the perceived complexity by automatically determining the optimal cutting strategy.
3Productivity
If automated tool path design is used, then productivity is improved, but material waste increases due to ineffective minimization of removal
Solution Approach 1:
The system changes multiple parameters simultaneously: cut height, cut depth, and tool path position. By varying these parameters across multiple step-up cuts, the algorithm optimizes material removal efficiency. The automated system adjusts these parameters to minimize waste while maintaining high productivity, eliminating the need for manual optimization.
Solution Approach 2:
The tool path calculation incorporates feedback from the workpiece geometry and limiting surface definitions. The system continuously evaluates the relationship between the current cut position and the offset/scallop surfaces, adjusting subsequent cuts to minimize material waste. This closed-loop optimization ensures that automated high-speed machining does not sacrifice material efficiency.
Data Source
AI summary
An automated computer-implemented method for generating commands for controlling a computer numerically controlled milling machine to fabricate a machined object from a workpiece, the machined object being configured to facilitate subsequent finishing into a finished object, the method including defining a surface of the finished object, defining an offset surface defining an inner limiting surface of the machined object, defining a scallop surface defining an outer limiting surface of the machined object and calculating a tool path for the milling machine which produces multiple step-up cuts in the workpiece resulting in the machined object, wherein surfaces of the machined object all lie between the inner limiting surface and the outer limiting surface and the number of step-up cuts in the workpiece and the areas cut in each of the step-up cuts are selected to generally minimize the amount of workpiece material that is removed from the workpiece.