Optimized Tool Motion Symmetry for Strip-Width-Max Mfg of Sculptured Surfaces with Non-Ball Tools Based on Envelope Approximation

The problem of machining complex surfaces with non-ball-end cutters by strip-width-maximization machining is formulated as a kind of surface fitting problem in which the tool surface envelope feature line approximates the design surface under the movement transform. The theory of surface envelope−approximation is proposed as a general method for optimizing tool movement in single-contact strip-width-maximization machining of sculptured surfaces with non-ball-end cutters. Based on the surface moving frame, the velocity equations and transformation matrices for the tool motion relative to the workpiece, described by the motion-invariant parameters of the tool surface and design surface, are derived. A functional extremum model for optimizing the tool position ensures continuous and symmetrical motion relative to the workpiece to achieve the highest machining efficiency and accuracy. Finally, a Matlab-based simulation example verifies the machining efficiency and accuracy of the envelope approximation theory.