Towards G¹-Continuous Multi-Strip Path-Planning for 5-Axis Flank CNC Machining of Free-Form Surfaces Using Conical Cutting Tools

Existing flank milling path-planning methods typically lead to tiny gaps or overlaps between neighboring paths, which causes artifacts and imperfections in the workpiece. We propose a new multi-strip path-planning method for 5-axis flank milling of free-form surfaces which targets G¹ (tangent-plane) continuity of the neighboring strips along shared boundaries. While for some geometries one cannot achieve G¹ continuity and high approximation quality at the same time, our optimization framework offers a good trade-off between machining accuracy in terms of distance error and the G¹ connection of neighboring strips. We demonstrate our algorithm on synthetic free-form surfaces as well as on industrial benchmark datasets, showing that we are able to meet fine industrial tolerances and simultaneously significantly reduce the kink angle of adjacent strips, and consequently to improve the surface finish in terms of smoothness.