Improved Five Axis–Rough Milling Process Efficacy: a Close-Bounded Volume (CBV) Evaluation Method Based on a Faceted Model

Roughing processes create workpieces that are similar to actual forms in short periods of time. However, the current method, which involves either three-axis or five-axis machines, is limited in regards to workpiece feed accessibility. Often, significant amounts of material are left on workpieces that can be removed. This paper presents a solution to this issue. By conducting a Close Bouded Volume (CBV) evaluation of an area for which a roughing process can be used, a tool path can be formed with a consideration of tool-path length. It can be done by using a point cloud as a cutter contact (CC) point. Tool orientations can be calculated based on a vector operation from a CC point in a CBV area to the nearest and highest CC point outside the CBV area. By orienting each tool on a formed CC point, interference detection can be used to avoid collisions and gouges that occur between feeds and workpieces on the tool path. Tool interference avoidance can be applied using rotation and translation methods until tools are free from interference. Then, from a CC point that is already free of interference, the avoidance can be tested using an actual rough machining process with a five-axis milling machine. According to this study's results, volume increases can be obtained in roughing so residual materials on workpieces can be reduced. Thus, this method improves disposal processes for residual materials. Moreover, it increases the efficacy of roughing processes.