Five-axis tool path and feed rate optimization based on the cutting force–area quotient potential field

Feed rate assignment in five-axis surface machining is constrained by many factors, among which a particularly critical one is the deflection cutting force on the tool: while a larger feed rate increases the machining productivity by shortening the total machining time, it nevertheless inevitably enlarges the deflection cutting force as well, which will cause the tool to be more prone to bending and the machine more prone to vibration, thus adversely degrading the surface finish quality. In this paper, we present a new five-axis tool path generation algorithm that strives to globally maximize feed rate for an arbitrary free-form surface while respecting a given deflection cutting force threshold. The crux of the algorithm is a new concept of the (cutting) force–area quotient function—at any cutter contact point on the surface, the maximal effective material removal rate (with respect to the deflection cutting force threshold) is a continuous function of the feed direction. This function induces a potential field on the surface and based on which an efficient tool path generation algorithm is designed. Preliminary experiments show that substantial reduction in total machining time can often be achieved by the proposed algorithm.