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AbstractThis paper discusses the application of geometry morphing techniques for the generation of intermediate steps for multi-axis rough milling operations. The typical roughing approach elaborates a 3-axis or 3-axis indexed tool path to remove the bulk of the material from the workpiece. These methods often lead to dynamically unfavorable intermediate geometry for deep cavity and/or taper-walled part shapes. The resulting ‘stairs’ shapes from these 3-axis methods cause a highly varying material removal volume during the finishing operations. Morphing techniques are investigated in this paper to generate smoothly varying intermediate geometry during the roughing phases of the machining process. These smooth intermediate surfaces advocate for applying 5-axis roughing methods instead of 3-axis methods.

3D Morphing for Generating Intermediate Roughing Levels in Multi-Axis Machining