5-axis NC machining of sculptured surface using non-ballendmill cutters(eg. facemilling cutters) is widely used in the machining of turbine blads and marine propellers. Since there are more degrees of freedom in 5-axis machining than in 3-axis machining, generating "optimum" cutter paths and finding desirable cutter positions become very important in order for an efficient use of 5-axis NC machines. Also critical in 5-axis NC machining are collision avoidance, gouging checking, and efficient kinematic solutions.
In this thesis we discuss the above issues in generating 5-axis CL data. They are: kinematics modeling of NC machine; inverse kinematics solution; interference between machine component and surface; cutter gouging; optimal CL data; joint smoothing; and cutter path planning, especially for approach and retreat;
A unique search method for obtaining optimal CL data is proposed. The proposed method has been successfully implemented in the machining of marine propellers on a dual 5-axis(ie, 9-axis) NC machine (the research is mainly based on the project "Development of CAM System for Machining of Marine Propellers with 9-axis NC Machine" funded by Hyundai Heavy Industry, Ulsan).
