Interference Detection in NC Machining of Freeform Surfaces Using an End Milling Cutter

This paper presents a systematic interference detection methodology for machining free-form surfaces on three-axis NC machines using an end-milling cutter. When a freeform surface is being milled, the interference may exist anywhere around the cutter circumference, in addition to the tool-driving plane. In this method, check lines instead of check planes are used to identify the potential interference areas on the sculptured surface to be machined. Therefore, the proposed approach greatly speeds the process of detecting the interference and improves the accuracy and reliability of machining. Geometric design processes of product and cutter size selection that are crucial to machining efficiency are also facilitated. The case study has demonstrated the validity of the proposed methodology and algorithms.