A new approach to generating arc length parameterized NURBS tool paths for efficient three-axis machining of smooth, accurate sculptured surfaces

With the development of a new function of computer numerical control controllers, nonuniform rational B-spline (NURBS) interpolation, NURBS tool path generation for sculptured surface machining is under extensive research. The common procedures of the current NURBS tool path planning methods are as follows: first, to find a group of cutter contact points on a sculptured surface; second, to calculate their corresponding cutter locations (CLs); then, to fit a NURBS tool path to the CLs within a prescribed tolerance; and finally, to inspect the tool path for possible gouge by the tool and delete the invalid path segments, if any. However, the NURBS tool path has the following problems: (a) although it passes through the discrete CLs of the theoretical CL path, the deviation along the two paths could be larger than the tolerance; (b) its parameter is not the arc length of the path; and (c) it is difficult to detect gouge along the NURBS path and to remove the invalid segments from it. Consequently, NURBS tool paths generated with the current methods of commercial computer-aided design/computer-aided manufacturing (CAD/CAM) software cannot be used to make smooth and accurate surfaces. To address these problems, this work proposes a new approach to generating arc length parameterized NURBS tool paths with high accuracy in terms of the theoretical CL paths and without gouge and interference. Two practical examples in this work clearly demonstrate the feasibility of this approach and the advantages of the generated NURBS tool paths. Therefore, this approach can be implemented into the CAD/CAM software to promote NURBS machining in industry.