Constrained Ruled Surface Reconstruction for 5-Axis NC Machining of Aero-Structure

We proposed a constrained ruled surface approximation algorithm for 5-axis machining of aero structure. Ruled surface is widely used in the design of aero structure. In practical model process, the regular ruled surface is usually split into some small fragmentary surfaces. The segmentation of the original surface mainly comes from some iterative boolean operations on the ruled surface. The segmentation destroys original parameter lines and leads into complex curved boundaries. Furthermore, the obtained fragmentary surfaces deviate from the original ruled surface because of the accuracy loss in the boolean operations of 3D CAD software. Some gaps between the small surfaces often appear. In manufacturing process, it is difficult to generating high-quality tool path for the surface with disordered parameter lines, curved boundaries and gaps. The proposed ruled surface approximation algorithm provides an effective way to reconstruct the smooth ruled surface. The constraints of boundary and smoothness are both considered. The ruled surface for simultaneous 5-axis machining is finally obtained. This algorithm have been integrated into CATIA V5 system and applied in practical manufacturing planning of aero-structures.