Evolution-based tool path and motion planning optimization for 5-axis CNC machining of free-form surfaces

Abstract

Manufacturing of free-form geometries using 5-axis Computer Numerically Controlled (CNC) machining brings challenges in path-and motion-planning as one typically wants to minimize the manufacturing time of the object under consideration, while keeping the machining error within fine machining tolerances that ranges in tens of microns. We propose an optimization-based pipeline that, for a given toroidal and/or cylindrical flat-end cutter, simultaneously optimizes its milling paths together with its local positioning represented by the rotation and tilt functions. The proposed strategy is validated on a variety of benchmark surfaces, with different hyperparameters for the objective function and initial conditions, showing that our results provide high-quality approximations of free-form geometries using by-construction non-colliding motions of the given tool.