Selection of an optimal set of cutting-tools for a general triangular pocket

The size(s) of the cutting-tool (end-mill) chosen for machining a given pocket has a significant impact on the machining time. However, the selection of cutting-tool sizes is typically based on human judgment and estimates, and is therefore prone to be conservative and non-optimal. The focus of this paper is on the development of a procedure for selection of an optimal set of cutting-tools for staircase milling of general triangular pockets with round corners, such that the machining time is minimized. We first derive analytical models for determining the time for machining the pocket using a given cutting-tool. Subsequently, we employ a dynamic-programming based approach that utilizes these analytical models to determine the best set of cutting-tools, from the available inventory of cutting-tools, to machine the pocket. The proposed approach can be extended for optimal selection of cutting-tools for rough-machining of 3-D sculptured cavities.