Tool tip gouging avoidance and optimal tool positioning for 5-axis sculptured surface machining

This article deals with locally optimal cutting positions and cutting directions for tool tip gouging avoidance in 5-axis sculptured surface machining. In order to measure the quality of tool positioning, this paper suggests a new concept of 'machined region width', which does not have the drawbacks of 'machined strip width'. The method evaluates the optimal cutting position of a flat endmill or toroidal endmill, where optimality is with respect to the avoidance of tool tip gouging. It is based on a second-order Taylor approximation of the design surface and multipoint tool positioning. The implementation and some illustrative examples are discussed.