Automated tool sequence selection for 3-axis machining of free-form pockets

This paper describes an efficient method to find the lowest cost tool sequence for rough machining free-form pockets on a 3-axis milling machine. The free-form pocket is approximated to within a predefined tolerance of the desired surface using series of 2.5-D layers of varying thicknesses that can be efficiently removed with flat-end milling cutters. A graph-based method finds an optimal sequence of tools for rough machining the approximated pocket. The algorithm used here can be tuned to suit any available tool set and preferred cost models. The tool sequence that is obtained is near optimal, and may take into account tool wear, as well as various overhead costs of the machine shop. (C) 2003 Elsevier Ltd. All rights reserved.