Optimal toolpath pattern identification for single island, sculptured part rough machining using fuzzy pattern analysis

In the manufacture of sculptured parts from prismatic stock, rough machining dominates the machining time due to the significant shape difference between the stock and part. For the sculptured part rough machining using 2.5D milling or contour-map machining, the appropriate selection of a toolpath pattern for each cutting layer can significantly improve productivity and lead to lower production costs. In the paper, various feasible toolpath patterns are investigated. An intelligent approach for automatically identifying the most productive toolpath pattern for a given cutting layer is introduced. The study is focused on sculptured parts with a single island and no seriously nonconvex shape. The method is based on fuzzy cutting layer shape pattern clustering and recognition. An example is used to illustrate the method.