Interference-free tool path generation in five-axis machining of a marine propeller

Abstract

The manufacture of a marine propeller typically requires long lead-time to generate five-axis tool paths. It usually takes several days to generate satisfactory tool paths with a general purpose CAD/CAM system. This paper proposes a novel methodology that generates effective five-axis tool paths for marine propellers. The machining of a propeller is accomplished in three steps: rough cut, semi-finish cut, and finish cut. For generating accurate finish cut tool paths, the proposed system computes check vectors that determine a maximum range of valid tool motion based upon tool size and passage width for each CL (Cutter Location) point along the tool path. Interference-free tool paths can be acquired by positioning the tool inside the two check vectors. The modelling capability for propellers is also of importance because it determines the eventual success or failure of the whole process. An iterative B-spline surface modelling technique is employed to improve the accuracy of the models and to increase the productivity. The proposed system generates interference-free tool paths with superior surface finish and reduces lead-time to manufacture a propeller. The system validation and sample results are given and discussed.