The generation of supplementary toolpaths for surface machining based on rapid prediction of scallop height distributions

This paper presents a generalized approach for rapid prediction of scallop height distributions. This methodology introduces the theory of mesh surface conformal mapping, effectively reducing the complexity of scallop height distributions prediction through dimension reduction from 3D space to a 2D parameter domain. It can predict scallop height distributions consistent with the order of cutter contact (CC) points, making it suitable for any type of toolpaths. Building upon this foundation, a novel method for generating supplemental machining toolpaths on intricate surfaces is further elaborated. This innovative method proficiently eliminates uncut regions that are often overlooked during toolpath generation, enhancing machining accuracy and efficiency without compromising on toolpath intervals. Finally, the validity and practicality of the proposed methods are rigorously verified through a combination of simulation and actual machining experiments. The experimental outcomes reveal that, when compared to prevalent commercial machining simulation software, the rapid prediction method introduced in this paper achieves a noteworthy improvement in calculation efficiency by approximately 50%. Furthermore, in contrast to the conventional strategy of enhancing toolpath accuracy by narrowing intervals, the supplementary toolpath generation method presented herein achieves a significant reduction in toolpath length by over 25%. This approach significantly augments the applicability and flexibility of toolpath optimization; it has important potential and value for improving the efficiency and accuracy of milling intricate surfaces.