Tool path generation for free form surfaces using Bézier curves/surfaces

Presented in this paper is a tool path generation method for multi-axis machining of free-form surfaces using Bézier curves and surfaces. The tool path generation includes two core steps. First is the forward-step function that determines the maximum distance, called forward step, between two cutter contact (CC) points with a given tolerance. The second component is the side step function which determines the maximum distance, called side step, between two adjacent tool paths with a given scallop height. Using the Bézier curves and surfaces, we generate cutter contact (CC) points for free-form surfaces and cutter location (CL) data files for post processing. Several parts are machined using a multi-axis milling machine. As part of the validation process, the tool paths generated from Bézier curves and surfaces are analyzed to compare the machined part and the desired part.