Optimal tool shape selection based on surface geometry for three-axis CNC machining

The 3D models of personalized custom products are unique, and to machine each model, a unique tool path is required. The manual generation of the tool paths is not economically viable for the mass production of these products; a viable option is to generate the tool path automatically. The tool paths depend on the tool shape, and an essential part of optimal machining of sculptured surfaces is the selection of the cutter shape. This paper focuses on optimal tool shape selection for the mass production of custom wooden signs. Ball nose and radiused end milling cutters are positioned at a given point along a defined tool path footprint. These tool positions are compared to determine which cutter achieves maximum material removal or surface roughness, i.e., scallop height. The scallops and the material removed are calculated for the cutter at all points along the tool path and are processed in order to determine the best tool or tools for machining the surface. Results show that the surface geometry has a great impact on the type of tool required to machine a surface.