(19)
(11)EP 2 681 683 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
08.04.2020 Bulletin 2020/15

(21)Application number: 12752319.9

(22)Date of filing:  22.02.2012
(51)Int. Cl.: 
G05B 19/4093  (2006.01)
(86)International application number:
PCT/IL2012/000087
(87)International publication number:
WO 2012/117391 (07.09.2012 Gazette  2012/36)

(54)

COMPUTERIZED TOOL PATH GENERATION

COMPUTERISIERTE WERKZEUGWEG-ERSTELLUNG

GÉNÉRATION DE TRAJECTOIRE D'OUTIL INFORMATISÉE


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(30)Priority: 28.02.2011 US 201113036726

(43)Date of publication of application:
08.01.2014 Bulletin 2014/02

(73)Proprietor: Solidcam Ltd.
60305 Or Yehuda (IL)

(72)Inventors:
  • BERMAN, Michael
    40300 Kfar Yona (IL)
  • OSOVLANSKI, Doron
    54423 Givat Shmuel (IL)
  • CALDERONE, Christopher Matthew
    Levittown PA 19054 (US)
  • CALDERONE, Anthony Joseph
    Yardley PA 19067 (US)

(74)Representative: J A Kemp LLP 
14 South Square Gray's Inn
London WC1R 5JJ
London WC1R 5JJ (GB)


(56)References cited: : 
US-A1- 2008 269 943
US-A1- 2008 269 943
US-B1- 6 428 252
US-A1- 2008 269 943
US-A1- 2010 191 359
US-B2- 7 237 989
  
  • IBARAKI S ET AL: "On the removal of critical cutting regions by trochoidal grooving", PRECISION ENGINEERING, ELSEVIER, AMSTERDAM, NL, vol. 34, no. 3, 1 July 2010 (2010-07-01), pages 467-473, XP027033380, ISSN: 0141-6359 [retrieved on 2010-01-28]
  • ELBER G ET AL: "MATHSM: medial axis transform toward high speed machining of pockets", COMPUTER AIDED DESIGN, ELSEVIER PUBLISHERS BV., BARKING, GB, vol. 37, no. 2, 1 February 2005 (2005-02-01), pages 241-250, XP027649802, ISSN: 0010-4485 [retrieved on 2005-02-01]
  • MARINAC.: 'Tool Path Strategies for High Speed Machining.' MODEM MACHINE SHOP., [Online] 15 February 2000, XP008171462 Retrieved from the Internet: <URL:http://www.mmsonline.com/articles/tool -path-strategies-for-high-speed-machining> [retrieved on 2012-07-09]
  
Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


Description


[0001] The present invention relates to systems and methodologies for automated tool path design and computer controlled machining and products produced thereby.

[0002] The following publications are believed to represent the current state of the art :

U.S. Patent Nos.: 4,745,558; 4,907,164; 5,363,308; 6,363,298; 6,447,223; 6,591,158; 7,451,013; 7,577,490 and 7,831,332; and

U.S. Published Patent Application No.: 2005/0256604.

US 2008/0269943 discloses engagement milling.



[0003] The present invention seeks to provide systems and methodologies for automated tool path design and computer controlled machining and products produced thereby.

[0004] According to the present invention, there are provided an automated computer-implemented method, apparatus, and an automated computer-controlled machine, as defined in the independent claims.

[0005] Optionally, responsive to consideration of at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece, the configuring also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of fabricating an object, whereby the cost is a combination of the cost of operating the machine for the duration of the fabrication and the cost of the wear inflicted on the tool during the fabrication.

[0006] Optionally, the tool path includes a plurality of tool path segments and configuring a tool path includes recursively configuring each of the tool path segments, and wherein responsive to consideration of at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece, configuring each of the tool path segments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of machining the each of the tool path segments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining.

[0007] Optionally, each of the tool path segments includes a plurality of tool path subsegments and recursively configuring each of the tool path segments includes recursively configuring each of the tool path subsegments, and wherein responsive to consideration of at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece, the configuring each of the tool path subsegments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and
minimizing the cost of machining the each of the tool path subsegments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining.

[0008] Optionally, the configuring includes minimizing, subject to other constraints, the rate of change of the engagement angle over time. Optionally, the configuring also includes gradually changing the feed speed of the tool corresponding to the changing engagement angle. Optionally, the configuring is also operative to maintain a generally constant work load on the tool. Optionally, the configuring is also operative to minimize the cost of fabricating an object, whereby the cost is a combination of the cost of operating the machine for the duration of the fabrication and the cost of the wear inflicted on the tool during the fabrication. The optional features referenced in this paragraph are also applicable to all appropriate claimed embodiments of the present invention.

[0009] Optionally, the tool path includes a plurality of tool path segments and configuring a tool path includes recursively configuring each of the tool path segments, and wherein the configuring each of the tool path segments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of machining the each of the tool path segments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining. The optional features referenced in this paragraph are also applicable to all appropriate claimed embodiments of the present invention.

[0010] Optionally, each of the tool path segments includes a plurality of tool path subsegments and recursively configuring each of the tool path segments includes recursively configuring each of the tool path subsegments, and wherein the configuring each of the tool path subsegments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of machining the each of the tool path subsegments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining. The preferred features referenced in this paragraph are also applicable to all appropriate claimed embodiments of the present invention.

[0011] Optionally, the configuring also includes considering at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece. The optional features referenced in this paragraph are also applicable to all appropriate claimed embodiments of the present invention.

[0012] Optionally, the method also includes configuring at least one trochoidal-like tool path for the rotating cutting tool in a remaining portion of the region of the workpiece which is removed by the tool moving along the trochoidal-like tool path.

[0013] Optionally, the at least one trochoidal-like tool path includes a plurality of trochoidal-like tool path segments, configuring an asymmetric spiral tool path includes recursively configuring each of the spiral tool path segments, and configuring at least one trochoidal-like tool path includes recursively configuring each of the trochoidal-like tool path segments, and wherein responsive to consideration of at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece, the configuring each of the tool path segments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of machining the each of the tool path segments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining.

[0014] Optionally, the method also includes directing the rotating cutting tool along at least one trochoidal-like tool path in a remaining portion of the region of the workpiece which is removed by the tool moving along the trochoidal-like tool path.

[0015] Optionally, the tool path configuration engine is also operative for configuring at least one trochoidal-like tool path for the rotating cutting tool in a remaining portion of the region of the workpiece which is removed by the tool moving along the trochoidal-like tool path.

[0016] Optionally, the configuring includes configuring the asymmetric spiral tool path and the at least one trochoidal-like tool path relative to the workpiece so that the engagement angle gradually varies between the maximum permitted engagement angle and the minimum permitted engagement angle.

[0017] Optionally, the controller is also operative for directing the rotating cutting tool along at least one trochoidal-like tool path in a remaining portion of the region of the workpiece which is removed by the tool moving along the trochoidal-like tool path.

[0018] Optionally, an object is fabricated also by directing the rotating cutting tool along at least one trochoidal-like tool path in a remaining portion of the region of the workpiece which is removed by the tool moving along the trochoidal-like tool path.

[0019] Optionally, the method includes the steps of selecting a region of the workpiece to be removed by a rotating cutting tool, selecting a first portion of the region to be removed by an asymmetric spiral tool path, and configuring at least one trochoidal-like tool path for removing a remaining portion of the region, and wherein the selecting a first portion of the region is operative to minimize the machining time necessary to remove the region.

[0020] Optionally, the method includes selecting a region of the workpiece to be removed by a rotating cutting tool, selecting a first portion of the region to be removed by an asymmetric spiral tool path, and directing the tool along at least one trochoidal-like tool path in a remaining portion of the region of the workpiece, and wherein selecting a first portion of the region is operative to minimize the machining time necessary to remove the region.

[0021] Optionally, the method includes the steps of considering the cross section of a desired object to be fabricated from a workpiece, defining isolated regions of the cross section on the workpiece surface which are not to be removed as islands, commencing configuring of a tool path in a region not having islands, and upon the tool path encountering an island, configuring a moat tool path which defines a moat surrounding the island.

[0022] Optionally, the method also includes defining a composite region including the island, the moat surrounding the island and regions already removed from the workpiece as a removed region and configuring a tool path to remove a remaining region of the workpiece, which remaining region does not include the removed region.

[0023] Optionally, the method includes the steps of identifying at least one open region for which a first machining time needed to remove the region is longer than a second machining time needed to divide the region into two independent regions by removing a separating channel by a rotating cutting tool between the two independent regions and removing the two independent regions, and defining in the region at least one separating channel extending between two points on edges of an external boundary of the region, thereby dividing the region into at least two independent regions.

[0024] Optionally, the method also includes configuring at least one trochoidal-like tool path for the rotating cutting tool in the separating channel which is removed by the tool moving along the trochoidal-like tool path.

[0025] Optionally, the at least one trochoidal-like tool path includes a plurality of trochoidal-like tool path segments and configuring at least one trochoidal-like tool path includes recursively configuring each of the trochoidal-like tool path segments, and wherein responsive to consideration of at least one of characteristics of the computer numerically controlled machine, rotating cutting tool and material of the workpiece, the configuring each of the tool path segments also includes minimizing, subject to other constraints, the rate of change of the engagement angle over time, gradually changing the feed speed of the tool corresponding to the changing engagement angle, maintaining a generally constant work load on the tool, and minimizing the cost of machining the each of the tool path segments, whereby the cost is a combination of the cost of operating the machine for the duration of the machining and the cost of the wear inflicted on the tool during the machining.

[0026] Optionally, the method, includes the steps of identifying at least one semi-open region for which a first machining time needed to remove the region by employing a trochoidal-like tool path is longer than a second machining time needed to isolate the region by removing separating channels between the region and all closed external boundary segments of the region and removing the remainder of the region, and defining in the region to be removed at least one separating channel between the region and all closed external boundary segments of the region, thereby defining a remaining open region to be removed.

[0027] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

Figs. 1A - 1S-2 are together a series of simplified illustrations which are helpful in understanding the invention;

Figs. 2A - 2L-2 are together another series of simplified illustrations which are helpful in understanding the invention;

Figs. 3A - 3D are simplified screen shots illustrating some aspects of the present invention; and

Figs. 4A and 4B are simplified illustrations of details of functionality illustrated more generally in certain ones of Figs. 1A - 1S-2 and Figs. 2A - 2L-2.



[0028] The present invention relates to various aspects of an automated computer-implemented method for generating commands for controlling a computer numerical controlled (CNC) machine to fabricate an object from a stock material, various aspects of a method for machining the stock material which employs the above commands, automated computer-implemented apparatus for generating the above commands, and a numerically-controlled machine operative to fabricate an object from a stock material by using the above commands.

[0029] The invention, in its various aspects, is described hereinbelow with respect to a series of drawings, which initially illustrate an example of an object to be fabricated, a simulated overlay of the object on a stock material to be machined and sequences of machining steps that are produced by commands generated in accordance with the present invention. It is appreciated that although sequential machining steps are illustrated, the invention is not limited to a machining method but extends as noted above to the generation of the commands, the apparatus, which generates them, and to the apparatus which carries them out.

[0030] The term "calculation" is used throughout to refer to the generation of commands which produce sequences of machining steps to be employed in the machining of a particular region of the stock material. The definitions "calculate", "calculation" and calculation are of corresponding meaning.

[0031] Figs. 1A and 1B are respective pictorial and top view illustrations of an object 100 which is an example of objects that can be fabricated in accordance with the present invention. The configuration of the object 100 is selected to illustrate various particular features of the present invention. It is noted that any suitable three-dimensional object that can be machined by a conventional 3-axis CNC machine tool may be fabricated in accordance with a preferred embodiment of the present invention.

[0032] As seen in Figs. 1A & 1B, the object 100 is seen to have a generally planar base portion 102 from which five protrusions, here designated by reference numerals 104, 106, 108, 110 and 112 extend. Fig. 1C shows stock material 114 overlaid by an outline of object 100.

[0033] In accordance with a preferred embodiment of the present invention, a tool path designer, using the automated computer-implemented method for generating commands for controlling a computer numerical controlled machine of the present invention, accesses a CAD drawing of the object 100 in a standard CAD format, such as SOLIDWORKS®. He selects a specific machine tool to be used in fabrication of the object 100 from a menu and selects a specific rotating cutting tool to carry out each machining function required to fabricate the object.

[0034] For the sake of simplicity, the illustrated object 100 is chosen to be an object that can be fabricated by a single machining function, it being appreciated that the applicability of the present invention is not limited to objects which can be fabricated by a single machining function.

[0035] The tool path designer then defines the geometry of the stock material to be used in fabrication of the object 100. This may be done automatically by the automated computer-implemented apparatus of the present invention or manually by the tool path designer. The tool path designer then specifies the material which constitutes the stock material, for example, INCONEL® 718. The present invention utilizes the choice of machine tool, rotating cutting tool and the material by the tool path designer to calculate various operational parameters, based on characteristics of the machine tool, rotating cutting tool and material.

[0036] In accordance with a preferred embodiment of the present invention, a series of display screens are employed to provide a display for the tool path designer, indicating the various operational parameters, such as minimum and maximum surface cutting speed, minimum and maximum chip thickness, minimum and maximum feed speed, minimum and maximum spindle rotational speed, minimum and maximum engagement angles between the rotating cutting tool and the workpiece, axial depth of cut, machining aggressiveness level. An example of such a series of display screens appears in Figs. 3A - 3D.

[0037] The tool path designer is given limited latitude in changing some of the parameters, such as particularly, the machining aggressiveness level. Preferably, the tool path designer may also instruct the system to select parameters for which, for example, optimization of machining time, wear inflicted on the cutting tool, machining cost or any combination thereof is achieved. It is appreciated that although for some of the operational parameters described hereinabove a range of values is displayed to the tool path designer, the present invention also calculates an optimal operational value for all of the operational parameters to be employed.

[0038] Once all of the parameters appearing on the screen, such as the display screens of Figs. 3A - 3D, are finalized, a tool path for machining the workpiece is calculated in accordance with a preferred embodiment of the present invention. The calculation of a tool path in accordance with a preferred embodiment of the present invention is described hereinbelow with reference to Figs. 1A - 1S-2 which illustrate the actual progression of tool path in stock material 114.

[0039] It is a particular feature of the present invention that the tool path is calculated recursively, whereby initially a first tool path segment of the tool path is calculated for an initial region of the workpiece, and thereafter a subsequent sequential tool path segment of the tool path is similarly calculated for an initial region of a remaining region of the workpiece. Additional subsequent sequential tool path segments are similarly calculated, until a tool path for machining the entire workpiece to the desired object has been calculated.

[0040] Initially, a first cross section of the stock material having the outline of the object 100 overlaid thereon and having a depth equal to the designated axial depth of cut is calculated. This cross section is illustrated schematically in Fig. 1D and is designated by reference numeral 116. Cross section 116 is characterized as having an external boundary 118 and a plurality of islands 105, 107, 109, 111 and 113 respectively corresponding to the cross sections of protrusions 104, 106, 108, 110 and 112 at the depth of cross section 116. It is appreciated that islands 105, 107, 109, 111 and 113 are offset externally to the cross sections of protrusions 104, 106, 108, 110 and 112 by a distance which is generally a bit larger than the radius of the rotating cutting tool, thereby when machining a tool path which circumvents the islands, a narrow finishing width remains to be finish machined at a later stage.

[0041] It is appreciated that the axial depth of cross section 116 constitutes a first step down which is a first phase in the machining of object 100. Throughout, the term "step down" is used to describe a single machining phase at a constant depth. As shown in Fig. 1C, the complete machining of object 100 requires two additional step downs corresponding to cross sections 119 and 120. Therefore, subsequent to the calculation of cross section 116, a second step down and thereafter a third step down are calculated, corresponding to cross sections 119 and 120. Preferably, the vertical distance between subsequent step downs is generally between 1 and 4 times the diameter of the rotating cutting tool.

[0042] In accordance with a preferred embodiment of the present invention, a machining region is initially automatically identified in cross section 116. There are preferably three types of machining regions which are classified by the characteristics of their exterior boundaries. Throughout, a segment of the boundary of a region through which the region can be reached by a rotating cutting tool from the outside of the region by horizontal progression of the rotating cutting tool is termed an "open edge". All other boundary segments are termed throughout as "closed edges".

[0043] The three types of machining regions are classified as follows:

Type I - an open region characterized in that the entire exterior boundary of the region consists solely of open edges;

Type II - a semi-open region characterized in that the exterior boundary of the region consists of both open edges and closed edges;

Type III - a closed region characterized in that the entire exterior boundary of the region consists solely of closed edges;



[0044] Preferably, a tool path to be employed in machining a region is calculated to comprise one or more tool path segments, wherein each tool path segment is one of a converging spiral tool path segment, a trochoidal-like tool path segment and a diverging spiral tool path segment. Generally, a converging spiral tool path segment is preferred when machining a Type I region, a trochoidal-like tool path segment is preferred when machining a Type II region, and a diverging spiral tool path is preferred when machining a Type III region.

[0045] The term "trochoidal-like" is used throughout to mean a trochoidal tool path or a modification thereof that retains a curved cutting path and a return path which could be either curved or generally straight.

[0046] As known to persons skilled in the art, the machining of spiral tool path segments is generally more efficient with respect to the amount of material removed per unit of time than the machining of trochoidal-like tool path segments for generally similar average stepovers. Therefore, the present invention seeks to maximize the area to be machined by spiral tool path segments.

[0047] A converging spiral tool path segment calculated to machine a Type I region preferably is a tool path segment which spirals inwardly from an external boundary of the region to an internal contour. The internal contour is preferably calculated as follows:

In a case where there are no islands within the external boundary of the Type I region, the internal contour is preferably calculated to be a small circle having a radius which is generally smaller than the radius of the cutting tool, and which is centered around the center of area of the region;

In a case where there is one island within the external boundary of the Type I region, and the shortest distance between the one island and the external boundary of the Type I region is longer than a selected fraction of the diameter of the rotating cutting tool, the internal contour is preferably calculated to be generally alongside the external boundary of the island; and

In a case where:

there is one island within the external boundary of the Type I region and the shortest distance between the single island and the external boundary of the Type I region is shorter than a selected fraction of the diameter of the rotating cutting tool; or

there is more than one island within the external boundary of the Type I region
the internal contour is preferably calculated to be a contour which is offset interiorly to the external boundary of the region by a distance which is generally equal to 1.5 radii of the rotating cutting tool.



[0048] Once the internal contour is calculated, it is automatically verified that the internal contour does not self intersect. In a case where the internal contour does self intersect at one or more locations, preferably a bottleneck is identified in the vicinity of each such self intersection. If the bottleneck does not overlap with an island, a separating channel is preferably calculated at each such bottleneck. A separating channel preferably divides the region into two Type I regions which can be machined independently of each other by separate converging spiral tool path segments. If the bottleneck does overlap with an island, the internal contour is preferably recalculated to be offset interiorly to the external boundary by generally half of the original offset. This process is repeated until an internal contour which does not self-intersect is calculated.

[0049] It is a particular feature of the present invention that a converging spiral tool path segment which spirals inwardly from an external boundary of a region to an internal contour is calculated to be a "morphing spiral". The term "morphing spiral" is used throughout to mean a spiral tool path segment which gradually morphs the geometrical shape of one boundary or contour to the geometrical shape of a second boundary or contour as the spiral tool path segment spirals therebetween. While various methods of morphing are known to persons skilled in the art, the present invention seeks to implement particular methods of morphing in accordance with preferred embodiments of the present invention, as described hereinbelow.

[0050] It is another particular feature of the present invention that the engagement angle of the cutting tool employed throughout the tool path segment is not fixed, but rather may vary between the predetermined minimum and maximum engagement angles over the course of the tool path segment. This varying of the engagement angle allows for varying stepovers over the course of the tool path segment, and thereby enables the tool path segment to morph between two generally dissimilar geometrical shapes. The term "stepover" is used throughout to designate the distance between sequential loops of a spiral tool path segment. It is appreciated that the cutting tool efficiency which is achieved by employing a morphing spiral tool path segment is generally significantly greater than the cutting tool efficiency which is achieved by employing a trochoidal-like tool path segment. It is also appreciated that where appropriate, an engagement angle which is generally close to the maximum engagement angle is preferred.

[0051] While it is appreciated that employing varying engagement angles over the course of a tool path segment may have a negative impact of increasing the wear of the cutting tool due to the varying mechanical load on the cutting tool and to chip thinning, it is a particular feature of the present invention that this negative impact is generally compensated for by automatically dynamically adjusting the feed velocity to correspond to the varying engagement angle. It is another particular feature of the present invention that the engagement angle is varied gradually over the course of the tool path segment, thereby preventing sudden and sharp changes in cutting tool load, and thereby further reducing excess wear of the cutting tool.

[0052] Returning now to the calculation of a converging spiral tool path segment employed to machine a Type I region, once an internal contour has been calculated, the number of loops to be included in a converging spiral tool path segment which spirals inwardly from the external boundary of the region to the internal contour is calculated preferably as illustrated in Fig. 4A.

[0053] As shown in Fig. 4A, a plurality of bridges 500 of a predefined density are each stretched from the internal contour 502 to the external boundary 504. A bridge point 506 of each of bridges 500 is initially defined as the point of intersection of bridge 500 with external boundary 504. The length of the longest bridge divided by the minimum stepover is generally equal to the maximum number of loops that can be included in the spiral tool path segment. The length of the shortest bridge divided by the maximum stepover is generally equal to the minimum number of loops which must be included in the spiral tool path. As described hereinabove, minimum and maximum engagement angles are determined based on information provided by the tool path designer, which angles determine the minimum and maximum stepover of the spiral tool path segment.

[0054] It is appreciated that the furthest distance, in any direction, from internal contour 502 which can be machined by a converging spiral tool path segment is the number of loops included in the converging spiral tool path segment multiplied by the maximum stepover. Areas between internal contour 502 and external boundary 504 beyond this furthest distance from the internal contour cannot be machined by the converging spiral tool path segment, and are therefore preferably machined by clipping prior to the machining of the converging spiral tool path segment. Throughout, the term "clipping" is used to define the calculation of machining of areas of a region which cannot be machined by an optimal spiral tool path segment. Typically, clipped areas are machined either by a trochoidal-like tool path segment, before the machining of the spiral tool path segment, or by machining a separating channel which separates the clipped area from the remainder of the region and by subsequently machining the separated clipped area separately by a spiral tool path segment.

[0055] Throughout, a parameter 'n' will be used to designate a possible number of loops to be included in a spiral tool path segment, wherein n is a number between the minimum number of loops which must be included in the spiral tool path segment and the maximum number of loops that can be included in the spiral tool path segment.

[0056] For each possible value of n, a first work time for a first machining method needed to machine the area between external boundary 504 and internal contour 502 is calculated by summing the time needed to machine the spiral tool path segment and the time needed to machine all clipped areas which were identified between external boundary 504 and internal contour 502 as described hereinabove. The optimal number of loops to be included in the spiral tool path segment is chosen to be the value of n for which the first calculated work time is the shortest.

[0057] In a case where the internal contour is calculated to be a small circle which is centered around the center of area of the region, a second work time for a second machining method is calculated by summing the work time needed to machine a separating channel extending along the shortest bridge connecting the external boundary to the internal contour, further extending through the small circle and then further extending along an opposite bridge up to an opposite segment of the external boundary, thus dividing the region into two independent Type I regions, and the work time needed to machine the two independent Type I regions. In a case where the second work time is shorter than the first work time, the second machining method is preferred over the first machining method.

[0058] Once the optimal number of loops to be included in the converging spiral tool path segment is chosen, clipped areas and tool paths for their removal are calculated as described hereinabove. Subsequently, a new external boundary defined by the clipped areas is calculated and all bridge points are updated accordingly to be located on the new external boundary. Thereafter, the actual path of the spiral tool path segment is calculated, as follows:
Initially, the bridge point 510 of a first bridge 512 is preferably selected as a first spiral point of spiral tool path segment 514. First bridge 512 is preferably selected to minimize the time required to move the cutting tool from its previous position. A possible second spiral point of spiral tool path segment 514 is calculated as a point on a second bridge 516, immediately adjacent to first bridge 512 in a climbing direction of the cutting tool from first bridge 512, which point is distanced from bridge point 517 of second bridge 516 along second bridge 516 by the length of second bridge 516 divided by the remaining number of loops to be included in tool path segment 514.

[0059] For the possible second spiral point, the engagement angle at which the cutting tool will engage the material by following the spiral tool path segment 514 from first spiral point 510 to the possible second spiral point is calculated. In a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, the possible second spiral point is chosen as the second spiral point, and a new linear subsegment 520 between first spiral point 510 and second spiral point is added to spiral tool path segment 514.

[0060] In a case where the engagement angle is less than the predetermined minimum engagement angle, a binary search for a second spiral point for which the calculated engagement angle is generally equal to the predetermined minimum engagement angle is performed. The binary search is performed between the possible second spiral point and a point on second bridge 516 distanced from bridge point 517 of second bridge 516 by the maximum stepover. Once a second spiral point is found, a new linear subsegment 520 between first spiral point 510 and second spiral point is added to spiral tool path segment 514.

[0061] In a case where the engagement angle is greater than the predetermined maximum engagement angle, a binary search for a second spiral point for which the calculated engagement angle is generally equal to the predetermined maximum engagement angle is performed. The binary search is performed between bridge point 517 of the second bridge 516 and the possible second spiral point. Once a second spiral point is found, a new linear subsegment 520 between first spiral point 510 and second spiral point is added to spiral tool path segment 514.

[0062] In a case where new linear subsegment 520 intersects with internal contour 502 of the region, the spiral tool path segment 514 is terminated at the point of intersection, possibly creating one or more separate unmachined residual areas generally adjacent to internal contour 502. For each such separate residual area, if the size of the separate residual area is larger than a predetermined small value, it is calculated to be machined by a trochoidal-like tool path segment.

[0063] In a case where new linear subsegment 520 intersects with an island, the calculation of spiral tool path segment 514 is terminated at the point of intersection, and a moat is calculated to commence at the point of intersection and circumvent the island. The remainder of the region for which a tool path has yet to be calculated is designated as a new Type I region to be calculated separately.

[0064] The term "moat" is used throughout to designate a trochoidal-like tool path segment which machines a channel generally adjacent to an island that circumvents the island, thereby separating the island from the remainder of the material which needs to be machined. The width of the moat is preferably at least 2.5 times the radius of the cutting tool and preferably at most 4 times the radius of the cutting tool. These values are predefined, however they may be modified by the tool path designer. It is a particular feature of the present invention that machining a moat around an island is operative to create a residual region which is of the same type as the original region. This is of particular value when machining a Type I region or a Type III region which are thus able to be generally machined by spiral tool path segments which are generally more efficient than trochoidal-like tool path segments.

[0065] Additionally, the machining of a moat to circumvent an island is effective in preventing the formation of two fronts of a machined region adjacent to the island, which may potentially form one or more long narrow residual walls between the two fronts. As known to persons skilled in the art, the formation of narrow residual walls is undesirable as machining them may lead to damage to the cutting tool and\or to the workpiece.

[0066] Once second spiral point has been calculated, the remaining number of loops to be included in the remainder of tool path segment 514 is updated. It is appreciated that the remaining number of loops may be a mixed number. The subsequent segments of the remainder of spiral tool path segment 514 are calculated recursively, whereby second spiral point is designated to be a new first point of the remainder of spiral tool path segment 514, and the bridge 530 immediately adjacent to second bridge 516 in a climbing direction of the cutting tool from second bridge 516 is designated to be a new second bridge. Additionally, second spiral point is designated as a new bridge point of second bridge 516, and the remaining region to be machined is recalculated.

[0067] The machining of a Type II region is calculated as follows:
Initially, a spiral machining time is calculated as the sum of the machining time needed for machining separating channels adjacent to all closed edges of the Type II region and the machining time needed for machining the remaining area of the region by a converging spiral tool path segment. Additionally, a trochoidal-like machining time is calculated as the machining time needed for machining the entire Type II region by a trochoidal-like tool path segment. If the spiral machining time is shorter than the trochoidal-like machining time, separating channels are calculated adjacent to all closed edges of the region, and the remaining separated area is calculated to be machined by a converging spiral tool path segment. If the spiral machining time is longer than the trochoidal-like machining time, a trochoidal-like tool path segment is calculated as follows:
The longest open edge of the region is selected as the "front" of the region. The remainder of the exterior boundary of the region is defined as the "blocking boundary". A starting end is selected as one of the two ends of the front, for which when machining along the front from the starting end to the opposite end would result in a climb milling tool path.

[0068] As shown in Fig. 4B a plurality of bridge lines 550 of a predefined density are each stretched from a front 552 across the region towards a blocking boundary 554. A bridge point 556 of each of bridges 550 is initially defined as the point of intersection of each of bridges 550 with front 552. A starting end 560 and an opposite end 562 are selected so that bridges 550 are ordered from starting end 560 to opposite end 562 in a climbing direction of the cutting tool. A single open trochoidal-like tool path segment 564 for machining an area adjacent to front 552 having a width which is generally equal to the maximum stepover is calculated by selecting a suitable point on each of bridges 550 and interconnecting the suitable points in the order of bridge lines 550 between starting end 560 and opposite end 562, as follows:
Initially, starting end 560 is preferably selected as a first point of the single trochoidal-like tool path segment 564. A possible second point of the trochoidal-like tool path segment 564 is calculated as a point on a first bridge 570, immediately adjacent to first point 560 in a climbing direction of the cutting tool from first point 560, which possible second point is distanced from bridge point 572 of the first bridge by the larger of the maximum stepover and the length of first bridge 570. In the illustrated example of Fig. 4B, the possible second point is calculated to be at the intersection 574 of first bridge 572 and blocking boundary 554.

[0069] For the possible second point, the engagement angle at which the cutting tool will engage the material by following the cutting tool path from the first point to the possible second point is calculated. In a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, the possible second point is chosen as the second point, and a new linear subsegment between first point 560 and the second point is added to the single trochoidal-like cutting tool path segment 564.

[0070] In a case where the engagement angle is less than the predetermined minimum engagement angle, a binary search for a second point for which the calculated engagement angle is generally equal to the predetermined minimum engagement angle is performed. The binary search is performed between the possible second point and a point on first bridge 570 distanced from bridge point 572 of first bridge 570, along first bridge 570, by the larger of the maximum stepover and the length of first bridge 570. Once a second point is found, a new linear subsegment between first point 560 and the second point is added to the single trochoidal-like cutting tool path segment 564.

[0071] In a case where the engagement angle is greater than the predetermined maximum engagement angle, a binary search for a second point for which the calculated engagement angle is generally equal to the predetermined maximum engagement angle is performed. The binary search is performed between bridge point 572 of first bridge 570 and the possible second point. Once a second point is found, a new linear subsegment between first point 560 and the second point is added to the single trochoidal-like cutting tool path segment 564.

[0072] In the illustrated example of Fig. 4B, intersection 574 is selected as the second point, and a new linear subsegment 580 between first point 560 and second point 574 is added to the single trochoidal-like cutting tool path segment 564.

[0073] Subsequently, calculation of the remainder of the single trochoidal-like tool path segment 564 is achieved by recursively performing the aforementioned calculation of tool path subsegments through suitable points on ordered bridges 550 up until opposite end 562 of selected front 552. In a case where the single trochoidal-like tool path segment 564 crosses an island, the single trochoidal-like tool path segment 564 is clipped at the intersecting points of the single trochoidal-like tool path segment 564 and the external boundary of the island, thereby creating two disjoint subsegments of the single trochoidal-like tool path segment 564. These two subsegments are then connected along a section of the external boundary of the island facing the front, which section is a closed edge.

[0074] The aforementioned calculation completes the calculation of a tool path segment for machining a part of the Type II region. At this point, the remainder of the Type II region to be machined is calculated, and a tool path for machining of the remainder of the Type II region is calculated recursively as described hereinabove. It is appreciated that the machining of the remainder of the Type II region requires repositioning of the cutting tool to a starting end of a front of the remainder of the Type II region. It is appreciated that repositioning techniques are well known to persons skilled in the art.

[0075] Referring now to the calculation of a tool path for machining of a Type III region, a diverging spiral tool path is preferred when machining Type III regions, as described hereinabove. A diverging spiral tool path segment calculated to machine a Type III region is a tool path segment which spirals outwardly from an innermost contour to an external boundary via a multiplicity of nested internal contours. The nested internal contours are calculated as follows:
A first nested internal contour is calculated to be a contour which is offset interiorly to the external boundary of the region by a distance which is generally equal to 1.5 radii of the cutting tool. Additional nested internal contours are then calculated recursively inwardly from the first nested internal contour, each nested internal contour being inwardly spaced from the nested internal contour immediately externally adjacent thereto by a distance which is generally equal to 1.5 radii of the rotating cutting tool. A last nested internal contour is calculated to be a contour having a center of area which is closer than 1.5 radii of the cutting tool to at least one point on the contour. Inwardly of the last nested internal contour, the innermost contour is calculated to be a small circle having a radius which is generally smaller than the radius of the cutting tool, and which is centered around the center of area of the last nested internal offset contour.

[0076] In a case where the innermost contour is either within the external boundary of an island or intersects with the external boundary of an island, a moat is calculated to circumvent the island, and the innermost contour is recalculated to be immediately external to the external boundary of the moat, such that the innermost contour does not intersect with any other islands. It is noted that nested internal contours which intersect with an external boundary of any island are discarded.

[0077] Once the nested internal contours have been calculated, the number of loops to be included in a diverging spiral tool path segment which will spiral outwardly from the innermost contour to the last nested internal offset contour is calculated preferably as follows:
A plurality of bridge lines are stretched from the innermost contour to a next internal offset contour immediately externally adjacent thereto. A bridge point of each bridge is initially defined as the point of intersection of the bridge with the innermost contour. The length of the longest bridge divided by the minimum stepover provides a theoretical maximum of the number of loops that can be theoretically included in the diverging spiral tool path. The length of the shortest bridge divided by the maximum stepover provides an absolute minimum of the number of loops which must be included in the diverging spiral tool path segment that is required to machine the entire area between the innermost contour and the next internal offset contour.

[0078] It is appreciated that the furthest distance, in any direction, from the innermost contour which can be reached by a diverging spiral tool path segment is the number of loops included in the diverging spiral tool path segment multiplied by the maximum stepover. Areas between the innermost contour and the next internal offset contour beyond this furthest distance cannot be machined by the diverging spiral tool path segment, and are preferably machined by clipping after the machining of the diverging spiral tool path segment.

[0079] Throughout, the parameter n is used to designate a possible number of loops to be included in the spiral tool path segment, wherein n is a number between the minimum number of loops which must be included in the spiral tool path segment and the maximum number of loops that can be included in the spiral tool path segment.

[0080] For each possible value of n, the work time needed to machine the area between the innermost contour and the next internal offset contour is calculated by summing the time needed to machine the spiral tool path segment and the time needed to machine all clipped areas which were identified between the innermost contour and the next internal offset contour as described hereinabove. The optimal value of loops to be included in the spiral tool path segment is chosen to be the value of n for which the calculated work time is the shortest.

[0081] Once the optimal value of loops to be included in the tool path segment is chosen, the actual path of the spiral tool path segment is calculated. Initially, the bridge point of a first bridge is preferably selected as a starting spiral point of the spiral tool path segment. The first bridge is preferably selected to minimize the time required to move the rotating cutting tool from its previous position. A possible second spiral point of the spiral tool path segment is calculated as a point on a second bridge, immediately adjacent to the first bridge in a climbing direction of the cutting tool from the first bridge, which point is distanced from the bridge point of the second bridge by the length of the second bridge divided by the remaining number of loops to be included in the tool path segment.

[0082] For the possible second spiral point, the engagement angle at which the cutting tool will engage the material by following the cutting tool path from the first spiral point to the possible second spiral point is calculated. In a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, the possible second spiral point is chosen as the second spiral point, and a new linear subsegment between the first spiral point and the second spiral point is added to the spiral cutting tool path segment.

[0083] In a case where the engagement angle is less than the predetermined minimum engagement angle, a binary search for a second spiral point for which the calculated engagement angle is generally equal to the predetermined minimum engagement angle is performed. The binary search is performed between the possible second spiral point and a point on the second bridge distanced from the bridge point of the second bridge by the maximum stepover. Once a second spiral point is found, a new linear subsegment between the first spiral point and the second spiral point is added to the spiral tool path segment.

[0084] In a case where the engagement angle is greater than the predetermined maximum engagement angle, a binary search for a second spiral point for which the calculated engagement angle is generally equal to the predetermined maximum engagement angle is performed. The binary search is performed between the bridge point of the second bridge and the possible second spiral point. Once a second spiral point is found, a new linear subsegment between the first spiral point and the second spiral point is added to the spiral tool path segment.

[0085] In a case where the new linear subsegment intersects with an island, the calculation of the spiral tool path segment is terminated at the point of intersection, where a moat is calculated to commence and circumvent the island. The remainder of the region for which a tool path has yet to be calculated is designated as a new Type III region to be calculated separately.

[0086] In a case where the new linear subsegment intersects with the next internal offset contour, an additional loop of the diverging spiral tool path segment is calculated, and the portions of the additional loop which are internal to the next internal offset contour define one or more uncalculated residual regions between the diverging spiral tool path segment and the next internal offset contour, which residual regions are each calculated as a Type II region, preferably by employing a trochoidal-like tool path segment. The portions of the additional loop which are internal to the next internal offset contour are connected along the next internal offset contour to form a continuous loop which is the final loop of the diverging spiral tool path segment.

[0087] Once the second spiral point has been calculated, the remaining number of loops to be included in the tool path segment is recalculated and the subsequent segments of the spiral cutting tool path segment are calculated recursively, whereby the second spiral point is designated to be a new starting point of the remainder of the spiral tool path segment, and the bridge immediately adjacent to the second bridge in a climbing direction of the cutting tool from the second bridge is designated to be the new second bridge. Additionally, the second spiral point is designated as the new bridge point of the second bridge, and the remaining region to be machined is recalculated.

[0088] Subsequently, calculation of the remainder of the diverging spiral tool path for the remainder of the region is achieved by recursively performing the aforementioned calculation of diverging spiral tool path segments through subsequent consecutive pairs of nested internal contours between the last nested internal offset contour and the external boundary of the region.

[0089] It is appreciated that all of the calculations of the tool paths described hereinabove produce piecewise linear tool paths. In cases where a piecewise linear tool path is not suitable for a particular workpiece being machined by a particular CNC machine, a smoothing approximation of the piecewise linear tool path may be calculated. Such approximation methods are well known to persons skilled in the art.

[0090] Returning now to the illustrated example of Fig. 1D, cross section 116 is initially identified as a Type I region which includes multiple protrusions. Therefore, a converging spiral tool path segment is calculated between the external boundary of the workpiece and a calculated internal contour, as the initial tool path segment. This calculation preferably begins with calculation of a spiral tool path segment which begins from a selected location just outside the periphery of cross section 116. Reference is made in this context to Figs. 1E-1 and 1E-2, which are respective isometric and top view illustrations of the stock material 114 overlaid by outline 121 of object 100 in which the initial spiral tool path segment is indicated generally by reference numeral 122. It is noted that the spiral tool path is indicated by solid lines, which represent the center of the rotating cutting tool, whose cross-sectional extent is designated by reference numeral 124 in Fig. 1E-2. The selected location, here designated by reference numeral 126, is preferably selected to minimize the time required to move the rotating cutting tool from its previous position.

[0091] In the illustrated example of Figs. 1E-1 and 1E-2, the initial tool path segment is a converging spiral segment which is calculated as described hereinabove. As shown in Figs. 1E-1 and 1E-2, initial spiral tool path segment 122, ultimately intersects with island 105 at intersecting point 130 at which point spiral tool path segment 122 is terminated. As shown in Figs. 1F-1 and 1F-2, a moat 132 which circumvents island 105 is calculated.

[0092] As shown in Figs. 1F-1 and 1F-2, an inner boundary 134 of moat 132 is calculated to be generally alongside the outer boundary of island 105. It is appreciated that a narrow offset remains between the island 105 and an inner boundary 134 of the moat, which may be finish machined at a later stage. The outer boundary 136 of moat 132 is calculated as being offset from inner boundary 134 by the moat width.

[0093] As shown in Figs. 1F-1 and 1F-2, the outer boundary 136 of moat 132 intersects with island 107 at points 138 and 139. Therefore, an additional moat 140 is calculated to circumvent island 107, whereby moats 132 and 140 are joined to form one continuous moat which circumvents islands 105 and 107. As clearly shown in Figs. 1F-1 and 1F-2, the combination of the initial spiral tool path segment 122 and subsequent moats 132 and 140 which circumvent islands 105 and 107 define a new Type I region which is designated by reference numeral 142.

[0094] Region 142 includes multiple islands 109, 111 and 113. As clearly shown in Figs. 1F-1 and 1F-2, a bottleneck 150 is detected in region 142. Therefore, as shown in Figs. 1G-1 and 1G-2, a separating channel 152 is calculated at the location of bottleneck 150, effectively dividing region 142 into two independent Type I regions designated by reference numerals 154 and 156.

[0095] Turning now to Figs. 1H-1 and 1H-2, it is shown that initially, a spiral tool path segment for region 154 is calculated, while the calculation of region 156 is deferred. As shown in Figs. 1H-1 and 1H-2, a starting point 160 is chosen and a spiral tool path segment 162 extends from initial point 160 generally along the external boundary of region 154 until intersecting with island 109 at intersecting point 164 at which point spiral tool path segment 162 is terminated. As shown in Figs. 1I-1 and 1I-2, a moat 166 which circumvents island 109 is calculated. The remainder of region 154 is identified as a Type I region designated by reference numeral 170.

[0096] Region 170 includes islands 111 and 113. As clearly shown in 11-1 and 11-2, a bottleneck 172 is detected in region 170. Therefore, as shown in 1J-1 and 1J-2, a separating channel 174 is calculated at the location of bottleneck 172, effectively dividing region 170 into two independent Type I regions designated by reference numerals 176 and 178.

[0097] Turning now to 1K-1 and 1K-2, it is shown that initially, a spiral path for machining region 176 is calculated, while the calculation of region 178 is deferred. As shown in Figs. 1K-1 and 1K-2, region 176 does not include any islands, therefore a converging spiral tool path segment is calculated to machine region 176 with the internal boundary of region 176 being a small circle 177 of a radius which is generally smaller than the radius of the tool, and which is centered around the center of area of region 176.

[0098] Subsequentially, a spiral tool path segment for region 178 is calculated. As shown in Figs. 1L-1 and 1L-2, a starting point 180 is chosen and a spiral tool path segment 182 is extended from initial point 180 generally along the external boundary of region 178 until intersecting with island 111 at intersecting point 184 at which point spiral tool path segment 182 is terminated. As shown in Figs. 1M-1 and 1M-2, a moat 186 which circumvents protrusion 110 is calculated.

[0099] It is appreciated that in a case where the external boundary of a moat is calculated to be in close proximity to the external boundary of the Type I region which includes the moat, a local widening of the moat is calculated to prevent the forming of a narrow residual wall between the moat and the external boundary of the region. As known to persons skilled in the art, the formation of narrow residual walls is undesirable as machining them may lead to damage to the cutting tool and \ or to the workpiece.

[0100] As seen in Figs. 1M-1 and 1M-2, the external boundary of moat 186 is calculated to be in close proximity to the external boundary of region 178. Therefore, moat 186 is locally widened up to the external boundary of region 178, along a narrow residual wall area 189 in which, without this widening, a narrow residual wall would be have been formed between moat 186 and the external boundary of region 178. Locally widened moat 186 divides region 178 into two independent Type I regions designated by reference numerals 190 and 192.

[0101] Turning now to Figs. 1N-1 and 1N-2, it is shown that initially, region 190 is calculated, while the calculation of region 192 is deferred. As shown in Figs. 1N-1 and 1N-2, two clipped areas of region 190 designated by numerals 196 and 198 are identified. Areas 196 and 198 are calculated to be machined by a trochoidal-like tool path segment prior to the machining of the remainder of region 190 by a spiral tool path segment.

[0102] The remainder of region 190 does not include any islands, therefore a converging spiral tool path segment is calculated to machine the remainder of region 190 with the internal boundary being a small circle 191 of a radius which is generally smaller than the radius of the tool, and which is centered around the center of area of the remainder of region 190.

[0103] Subsequentially, a spiral tool path segment for region 192 is calculated. As shown in Figs. 1O-1 and 1O-2, one area of region 192, designated by numeral 200 is identified by clipping. Area 200 is calculated to be machined by a trochoidal-like tool path segment prior to the machining of the remainder of region 192 by a spiral tool path segment.

[0104] Additionally, as shown in Figs. 1P-1 and 1P-2, an additional area of region 192, designated by numeral 202 is identified by clipping. However, it is calculated that area 202 would be more efficiently machined as a separate Type I region. Therefore, a separating channel 210 which divides the remainder of region 192 into two Type I regions designated by numerals 202 and 214 is calculated. Region 202 does not include any protrusions, therefore, as shown in Figs. 1Q-1 and 1Q-2, a converging spiral tool path segment is calculated to machine region 202 with the internal boundary being a small circle 213 of a radius which is generally smaller than the radius of the tool, and which is centered around the center of area of region 202.

[0105] It is calculated that machining a separating channel 210 and machining region 202 as a Type I region results in a machining time which is shorter than the machining time of region 202 by a trochoidal-like tool path segment.

[0106] Turning now to Figs. 1R-1 and 1R-2, it is shown that region 214 includes one island 113 which is generally centrally located within region 214. Therefore, a converging spiral tool path segment 216 is calculated to machine region 214 with the internal boundary being generally alongside the external perimeter of island 113. As shown in Fig 1R-2, spiral tool path segment 216, ultimately intersects with island 113 at intersecting point 218 at which point spiral tool path segment 216 is terminated. It is appreciated that after machining segment 216, there may remain one or more Type II regions adjacent to island 113 which are machined by trochoidal-like tool path segments.

[0107] Turning now to Figs. 1S-1 and 1S-2, it is shown that, the machining of region 156 is calculated. As shown in Figs. 1S-1 and 1S-2, a clipped area of region 156 designated by numeral 230 is identified by clipping. Area 230 is preferably calculated to be machined by a trochoidal-like tool path segment, and the remainder of region 156 is then calculated to be machined by a spiral tool path segment.

[0108] It is appreciated that the calculation described hereinabove constitutes the calculation of a tool path for the machining of a first step down which is a first phase in the machining of object 100. Throughout, the term "step down" is used to describe a single machining phase at a constant depth. As shown in Fig. 1C, the complete machining of object 100 requires three step downs. Therefore, subsequent and similar to the calculation described hereinabove, the tool path designer calculates the machining of second step down 119 and thereafter of third step down 120, thereby completing the entire rough machining of object 100. Preferably, the vertical distance between subsequent step downs is generally between 1 and 4 times the diameter of the cutting tool.

[0109] It is appreciated that following the rough machining of a workpiece, an additional stage of rest rough machining is calculated, which reduces the large residual steps created by the series of step downs on the sloping surfaces of object 100.

[0110] Reference is now made to Figs. 2A - 2L-2, which illustrate the calculation of another tool path in accordance with a preferred embodiment of the present invention. Figs. 2A and 2B are respective isometric and top view illustrations of an object 400, which is another example of objects that can be fabricated in accordance with the present invention. The configuration of the object 400 is selected to illustrate additional various particular features of the present invention. It is noted that any suitable three-dimensional object that can be machined by a conventional 3-axis machine tool may be fabricated in accordance with a preferred embodiment of the present invention.

[0111] As seen in Figs. 2A & 2B, the object 400 is seen to have a generally planar base portion 402 from which one protrusion, here designated by reference numeral 404, extends. Fig. 2C shows stock material overlaid by a cross section 420 of object 400. Cross section 420 is characterized as having an external boundary 422 and an island 405 corresponding to the cross section of protrusion 404 at the depth of cross section 420.

[0112] In the illustrated example of Fig. 2C, cross section 420 is initially identified as a Type III region 424 which includes one island 405. As described hereinabove, a plurality of nested offset contours is calculated between the external boundary 422 of region 424 and an innermost contour of region 424. The innermost contour is initially calculated to be overlapping with the external boundary of island 405. Therefore, as shown in Figs 2D-1 and 2D-2, a moat 428 is calculated to circumvent island 405, and the innermost contour 430 is calculated to be immediately external to the external boundary of moat 428.

[0113] As shown in Figs. 2D-1 and 2D-2, innermost contour 430 and nested internal contour 440, external to innermost contour 430, define a Type III region 442. As shown in Figs. 2E-1 and 2E-2, a diverging tool path segment 443 is initially calculated to spiral outwardly between innermost contour 430 and nested internal contour 440, thereby creating two residual regions 444 and 446. As shown in Figs. 2F-1 and 2F-2, residual region 444 is calculated to be machined as a Type II region by employing a trochoidal-like tool path segment. Similarly, as shown in Figs. 2G-1 and 2G-2, residual region 446 is calculated to be machined as a Type II region by employing a trochoidal-like tool path segment.

[0114] Turning now to Figs. 2H-1 and 2H-2, it is shown that a diverging spiral tool path segment is calculated to machine a Type III region 448 defined between nested internal contour 440 and nested internal contour 450. Subsequently, as shown in Figs. 2I-1 and 2I-2, a diverging spiral tool path segment is similarly calculated to machine a Type III region 452 defined between nested internal contour 450 and nested internal contour 460.

[0115] Turning now to Figs. 2J-1 and 2J-2, it is shown that a diverging tool path segment is calculated to machine a Type III region 468 defined between nested internal contour 460 and external boundary 422, thereby creating two residual regions 470 and 472. As shown in Figs. 2K-1 and 2K-2, residual region 470 is calculated to be machined as a Type II region by employing a trochoidal-like tool path segment. Similarly, as shown in Figs. 2L-1 and 2L-2, residual region 472 is calculated to be machined as a Type II region by employing a trochoidal-like tool path segment, thereby completing the calculation of the machining of object 400.

[0116] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather, the invention also includes various combinations and subcombinations of the features described hereinabove that are within the scope of the claims.


Claims

1. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece, the method comprising the following two groups of steps:

the steps of:

selecting a maximum permitted engagement angle between a rotating cutting tool and said workpiece;

selecting a minimum permitted engagement angle between said rotating cutting tool and said workpiece; and

configuring a tool path for said rotating cutting tool relative to said workpiece in which an engagement angle between said rotating cutting tool and said workpiece gradually varies between said maximum permitted engagement angle and said minimum permitted engagement angle; and

the steps of:

selecting a region of said workpiece to be removed by said rotating cutting tool; and

configuring an asymmetric converging spiral tool path comprising a plurality of loops for said rotating cutting tool in said region of said workpiece, which asymmetric spiral tool path maximizes a portion of said region of said workpiece which is removed by said rotating cutting tool moving along said asymmetric spiral tool path;

wherein the engagement angle varies to thereby vary the distance between sequential loops multiple times over the course of the tool path to allow the tool path to morph between two dissimilar geometrical shapes;

wherein a number of loops to be included in the converging spiral tool path segment is calculated by the following steps:

defining a plurality of bridges (500) of a predefined density from an internal contour (502) to an external boundary (504);

defining a bridge point (506) as the point of intersection of each bridge (500) with the external boundary (504);

defining the maximum number of loops as the length of the longest bridge divided by the minimum stepover:

defining the minimum number of loops as the length of the shortest bridge divided by the maximum stepover:

calculating for each possible value of the number of loops between the maximum and the minimum number of loops, a first work time needed to machine the area between external boundary (504) and internal contour (502) by summing the time needed to machine the spiral tool path segment and the time needed to machine any portion of the region which cannot be machined by the calculated spiral tool path;

selecting the optimal number of loops of the spiral tool path segment as the value for which the first calculated work time is the shortest; and

wherein the actual path of the spiral tool path segment is calculated as follows:

selecting the bridge point (510) of a first bridge (512) as a first spiral point of spiral tool path segment (514), wherein first bridge (512) is selected to minimize the time required to move the cutting tool from its previous position;

calculating a possible second spiral point of spiral tool path segment (514) as a point on a second bridge (516), immediately adjacent to first bridge (512) in a climbing direction of the cutting tool from the first bridge (512), which point is distanced from the bridge point (517) of the second bridge (516) by the length of second bridge (516) divided by the remaining number of loops to be included in tool path segment (514);

calculating the engagement angle at which the cutting tool will engage the material by following the spiral tool path segment (514) from first spiral point (510) to the possible second spiral point:

in a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, choosing the possible second spiral point as the second spiral point (518), and adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is less than the predetermined minimum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is greater than the predetermined minimum engagement angle between the possible second spiral point and a point on the second bridge distanced from the bridge point by the maximum stepover; once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is greater than the predetermined maximum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is less than the predetermined maximum engagement angle between the bridge point (517) of the second bridge (516) and the possible second spiral point: once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the new linear subsequent (520) intersects with internal contour (502) of the region, terminating the spiral tool path segment (514) at the point of intersection;

once the second spiral point (518) has been calculated, updating the remaining number of loops to be included in the remainder of tool path segment (514); recursively calculating the subsequent segments of the remainder of spiral tool path segment (514) taking as first point the second spiral point.


 
2. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 1 and wherein the method comprises at least one of the following four groups of steps:

the steps of:

identifying at least one semi-open region for which a first machining time needed to remove said at least one semi-open region by employing a trochoidal-like tool path is longer than a second machining time needed to isolate said at least one semi-open region by removing separating channels between said at least one semi-open region and all closed external boundary segments of said at least one semi-open region and removing the remainder of said at least one semi-open region; and

defining in said at least one semi-open region to be removed at least one separating channel between said at least one semi-open region and all closed external boundary segments of said at least one semi-open region, thereby defining a remaining open region to be removed;

the steps of:

selecting a region of said workpiece to be removed by said rotating cutting tool;

selecting a first portion of said region of said workpiece to be removed by an asymmetric spiral tool path; and

configuring at least one trochoidal-like tool path for removing a remaining portion of said region of said workpiece;

wherein said selecting a first portion of said region is operative to minimize a machining time necessary to remove said region of said workpiece;

the steps of:

considering a cross section of said object to be fabricated from said workpiece;

defining isolated regions of said cross section on a surface of said workpiece which are not to be removed as islands;

commencing configuring of a tool path in a region not having islands; and

upon said tool path encountering an island, configuring a moat tool path which defines a moat surrounding said island; and

the steps of:

identifying at least one open region for which a first machining time needed to remove said at least one open region is longer than a second machining time needed to divide said at least one open region into two independent regions by removing a separating channel by said rotating cutting tool between said two independent regions and removing said two independent regions; and

defining in said at least one open region at least one separating channel extending between two points on edges of an external boundary of said at least one open region, thereby dividing said at least one open region into at least two independent regions.


 
3. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 2 and wherein the method comprises at least two of said four groups of steps.
 
4. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 1 - 3 and wherein responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring a tool path also includes at least one of:

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle;

maintaining a generally constant work load on said rotating cutting tool; and

minimizing a cost of fabricating said object, whereby said cost is a combination of a cost of operating said machine for the duration of said fabricating and a cost of wear inflicted on said rotating cutting tool during said fabricating.


 
5. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 1 - 4 and wherein:

said tool path comprises a plurality of tool path segments; and

said configuring a tool path comprises recursively configuring each of said tool path segments; and

responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring each of said tool path segments also includes:

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle; and

maintaining a generally constant work load on said rotating cutting tool.


 
6. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 5 and wherein:

each of said tool path segments comprises a plurality of tool path subsegments; and

said recursively configuring each of said tool path segments comprises recursively configuring each of said tool path subsegments; and

responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring each of said tool path subsegments also includes at least one of :

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle; and

maintaining a generally constant work load on said rotating cutting tool.


 
7. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 2 - 6 and wherein:

said asymmetric spiral tool path comprises a plurality of spiral tool path segments;

said at least one trochoidal-like tool path comprises a plurality of trochoidal-like tool path segments;

said configuring an asymmetric spiral tool path comprises recursively configuring each of said spiral tool path segments; and

said configuring at least one trochoidal-like tool path comprises recursively configuring each of said trochoidal-like tool path segments.


 
8. An automated computer-implemented method for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 2 - 7 and further comprising the steps of:

defining a composite region including said island, said moat surrounding said island and regions already removed from said workpiece as a removed region; and

configuring a tool path to remove a remaining region of said workpiece, which remaining region does not comprise said removed region.


 
9. Automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece, the apparatus comprising:

a tool path configuration engine operative for selecting a region of said workpiece to be removed by a rotating cutting tool and for the combination of:

configuring a tool path for said rotating cutting tool relative to said workpiece in which an engagement angle gradually varies between a preselected maximum permitted engagement angle and a preselected minimum permitted engagement angle; and

configuring an asymmetric converging spiral tool path comprising a plurality of loops for said rotating cutting tool in said region of said workpiece, which spiral tool path maximizes the portion of said region of said workpiece which is removed by said rotating cutting tool moving along said asymmetric spiral tool path;

wherein the engagement angle varies to thereby vary the distance between sequential loops multiple times over the course of the tool path to allow the tool path to morph between two dissimilar geometrical shapes;

wherein the apparatus is configured to calculate a number of loops to be included in the converging spiral tool path segment by the following steps:

defining a plurality of bridges (500) of a predefined density from an internal contour (502) to an external boundary (504);

defining a bridge point (506) as the point of intersection of each bridge (500) with the external boundary (504);

defining the maximum number of loops as the length of the longest bridge divided by the minimum stepover:

defining the minimum number of loops as the length of the shortest bridge divided by the maximum stepover:

calculating for each possible value of the number of loops between the maximum and the minimum number of loops, a first work time needed to machine the area between external boundary (504) and internal contour (502) by summing the time needed to machine the spiral tool path segment and the time needed to machine any portion of the region which cannot be machined by the calculated spiral tool path;

selecting the optimal number of loops of the spiral tool path segment as the value for which the first calculated work time is the shortest; and

wherein the apparatus is configured to calculate the actual path of the spiral tool path segment as follows:

selecting the bridge point (510) of a first bridge (512) as a first spiral point of spiral tool path segment (514), wherein first bridge (512) is selected to minimize the time required to move the cutting tool from its previous position;

calculating a possible second spiral point of spiral tool path segment (514) as a point on a second bridge (516), immediately adjacent to first bridge (512) in a climbing direction of the cutting tool from the first bridge (512), which point is distanced from the bridge point (517) of the second bridge (516) by the length of second bridge (516) divided by the remaining number of loops to be included in tool path segment (514);

calculating the engagement angle at which the cutting tool will engage the material by following the spiral tool path segment (514) from first spiral point (510) to the possible second spiral point:

in a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, choosing the possible second spiral point as the second spiral point (518), and adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is less than the predetermined minimum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is greater than the predetermined minimum engagement angle between the possible second spiral point and a point on the second bridge distanced from the bridge point by the maximum stepover; once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is greater than the predetermined maximum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is less than the predetermined maximum engagement angle between the bridge point (517) of the second bridge (516) and the possible second spiral point: once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the new linear subsequent (520) intersects with internal contour (502) of the region, terminating the spiral tool path segment (514) at the point of intersection;

once the second spiral point (518) has been calculated, updating the remaining number of loops to be included in the remainder of tool path segment (514); recursively calculating the subsequent segments of the remainder of spiral tool path segment (514) taking as first point the second spiral point.


 
10. Automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 9 and wherein the method comprises at least one of the following combinations:

the combination of:

identifying at least one semi-open region for which a first machining time needed to remove said at least one semi-open region by employing a trochoidal-like tool path is longer than a second machining time needed to isolate said at least one semi-open region by removing separating channels between said at least one semi-open region and all closed external boundary segments of said at least one semi-open region and removing the remainder of said at least one semi-open region; and

defining in said at least one semi-open region to be removed at least one separating channel between said at least one semi-open region and all closed external boundary segments of said at least one semi-open region, thereby defining a remaining open region to be removed;

the combination of:

selecting a first portion of said region of said workpiece to be removed by an asymmetric spiral tool path; and

configuring at least one trochoidal-like tool path for removing a remaining portion of said region of said workpiece, wherein said selecting a first portion of said region of said workpiece is operative to minimize a machining time necessary to remove said region of said workpiece;

the combination of:

considering a cross section of said object to be fabricated from said workpiece;

defining isolated regions of said cross section on a surface of said workpiece which are not to be removed as islands;

commencing configuring of a tool path in a region not having islands; and

upon said tool path encountering an island, configuring a moat tool path which defines a moat surrounding said island; and

the combination of:

identifying at least one open region for which a first machining time needed to remove said at least one open region is longer than a second machining time needed to divide said at least one open region into two independent regions by removing a separating channel by said rotating cutting tool between said two independent regions and removing said two independent regions; and

defining in said at least one open region at least one separating channel extending between two points on edges of an external boundary of said at least one open region, thereby dividing said at least one open region into at least two independent regions.


 
11. An automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 10 and wherein said configuring a tool path includes, responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring each of said tool path segments, at least one of:

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle;

maintaining a generally constant work load on said rotating cutting tool; and

minimizing a cost of fabricating said object, whereby said cost is a combination of a cost of operating said machine for the duration of said fabricating and a cost of wear inflicted on said rotating cutting tool during said fabricating.


 
12. An automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 9 - 11 and wherein:

said tool path comprises a plurality of tool path segments; and

said configuring a tool path comprises recursively configuring each of said tool path segments; and

said configuring each of said tool path segments also includes, responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring each of said tool path segments, at least one of:

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle; and

maintaining a generally constant work load on said rotating cutting tool.


 
13. An automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to claim 12 and wherein:

each of said tool path segments comprises a plurality of tool path subsegments; and

said recursively configuring each of said tool path segments comprises recursively configuring each of said tool path subsegments; and

said configuring each of said tool path subsegments also includes, responsive to consideration of at least one of characteristics of said computer numerical controlled machine, said rotating cutting tool and material of said workpiece, said configuring each of said tool path segments, at least one of:

minimizing, subject to other constraints, a rate of change of said engagement angle over time;

gradually changing a feed speed of said rotating cutting tool corresponding to changes in said engagement angle; and

maintaining a generally constant work load on said rotating cutting tool.


 
14. An automated apparatus for generating commands for controlling a computer numerical controlled machine to fabricate an object from a workpiece according to any of claims 10 - 13 and wherein said configuration engine is also operative for:

defining a composite region including said island, said moat surrounding said island and regions already removed from said workpiece as a removed region; and

configuring a tool path to remove a remaining region of said workpiece, which remaining region does not comprise said removed region.


 
15. An automated computer-controlled machine to fabricate an object from a workpiece, the machine comprising:
a controller operative for selecting a region of said workpiece to be removed by a rotating cutting tool; and for:

the combination of:

directing said rotating cutting tool along an asymmetric converging spiral tool path comprising a plurality of loops in said region of said workpiece, which spiral tool path maximizes a portion of said region of said workpiece which is removed by said rotating cutting tool moving along said asymmetric spiral tool path;

directing said rotating cutting tool along a tool path relative to said workpiece in which an engagement angle between said rotating cutting tool and said workpiece gradually varies between a preselected maximum permitted engagement angle and a preselected minimum permitted engagement angle;

wherein the engagement angle varies to thereby vary the distance between sequential loops multiple times over the course of the tool path to allow the tool path to morph between two dissimilar geometrical shapes;

wherein the controller is configured to calculate a number of loops to be included in the converging spiral tool path segment by the following steps:

defining a plurality of bridges (500) of a predefined density from an internal contour (502) to an external boundary (504);

defining a bridge point (506) as the point of intersection of each bridge (500) with the external boundary (504);

defining the maximum number of loops as the length of the longest bridge divided by the minimum stepover:
defining the minimum number of loops as the length of the shortest bridge divided by the maximum stepover:

calculating for each possible value of the number of loops between the maximum and the minimum number of loops, a first work time needed to machine the area between external boundary (504) and internal contour (502) by summing the time needed to machine the spiral tool path segment and the time needed to machine any portion of the region which cannot be machined by the calculated spiral tool path;

selecting the optimal number of loops of the spiral tool path segment as the value for which the first calculated work time is the shortest; and

wherein the controller is configured to calculate the actual path of the spiral tool path segment as follows:

selecting the bridge point (510) of a first bridge (512) as a first spiral point of spiral tool path segment (514), wherein first bridge (512) is selected to minimize the time required to move the cutting tool from its previous position;

calculating a possible second spiral point of spiral tool path segment (514) as a point on a second bridge (516), immediately adjacent to first bridge (512) in a climbing direction of the cutting tool from the first bridge (512), which point is distanced from the bridge point (517) of the second bridge (516) by the length of second bridge (516) divided by the remaining number of loops to be included in tool path segment (514);

calculating the engagement angle at which the cutting tool will engage the material by following the spiral tool path segment (514) from first spiral point (510) to the possible second spiral point:

in a case where the calculated engagement angle is between the predetermined minimum and maximum engagement angles, choosing the possible second spiral point as the second spiral point (518), and adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is less than the predetermined minimum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is greater than the predetermined minimum engagement angle between the possible second spiral point and a point on the second bridge distanced from the bridge point by the maximum stepover; once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the engagement angle is greater than the predetermined maximum engagement angle, performing a binary search for a second spiral point for which the calculated engagement angle is less than the predetermined maximum engagement angle between the bridge point (517) of the second bridge (516) and the possible second spiral point: once a second spiral point (518) is found, adding a new linear subsequent (520) between first spiral point (510) and second spiral point (518) to spiral tool path segment (514);

in a case where the new linear subsequent (520) intersects with internal contour (502) of the region, terminating the spiral tool path segment (514) at the point of intersection;

once the second spiral point (518) has been calculated, updating the remaining number of loops to be included in the remainder of tool path segment (514); recursively calculating the subsequent segments of the remainder of spiral tool path segment (514) taking as first point the second spiral point.


 
16. A method for machining a workpiece employing a computer controlled machine tool, the method comprising:

selecting a region of said workpiece to be removed by a rotating cutting tool;

generating commands according to any one of claims 1-8; and

directing, using the generated commands, said rotating cutting tool along an asymmetric spiral tool path comprising a plurality of loops in said region of said workpiece, which spiral tool path maximizes a portion of said region of said workpiece which is removed by said rotating cutting tool moving along said asymmetric spiral tool path;

wherein an engagement angle between said rotating cutting tool and said workpiece gradually varies between a preselected maximum permitted engagement angle and a preselected minimum permitted engagement angle;

wherein the engagement angle varies to thereby vary the distance between sequential loops multiple times over the course of the tool path to allow the tool path to morph between two dissimilar geometrical shapes.


 


Ansprüche

1. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück, wobei das Verfahren die folgenden zwei Gruppen von Schritten umfasst:

die Schritte zum:

Auswählen eines maximal zulässigen Eingriffswinkels zwischen einem rotierenden Schneidwerkzeug und dem Werkstück;

Auswählen eines minimal zulässigen Eingriffswinkels zwischen dem rotierenden Schneidwerkzeug und dem Werkstück; und

Konfigurieren eines Werkzeugwegs für das rotierende Schneidwerkzeug relativ zu dem Werkstück, bei dem ein Eingriffswinkel zwischen dem rotierenden Schneidwerkzeug und dem Werkstück allmählich zwischen dem maximal zulässigen Eingriffswinkel und dem minimal zulässigen Eingriffswinkel variiert; und

die Schritte zum:

Auswählen eines Bereichs des Werkstücks, der durch das rotierende Schneidwerkzeug entfernt werden soll; und

Konfigurieren eines asymmetrischen, konvergierenden, spiralförmigen Werkzeugwegs, der eine Vielzahl von Schleifen für das rotierende Schneidwerkzeug in dem Bereich des Werkstücks umfasst, wobei der asymmetrische spiralförmige Werkzeugweg einen Teil des Bereichs des Werkstücks maximiert, der durch das rotierende Schneidwerkzeug, das sich entlang des asymmetrischen, spiralförmigen Werkzeugwegs bewegt, entfernt wird;

wobei der Eingriffswinkel variiert, um dadurch den Abstand zwischen aufeinanderfolgenden Schleifen mehrmals über den Verlauf des Werkzeugwegs zu variieren, um es dem Werkzeugweg zu ermöglichen, sich zwischen zwei unterschiedlichen geometrischen Formen zu wandeln;

wobei eine Anzahl von Schleifen, die in das konvergierende spiralförmige Werkzeugwegsegment einzubeziehen sind, durch die folgenden Schritte berechnet wird:

Definieren einer Vielzahl von Brücken (500) mit einer vordefinierten Dichte von einer Innenkontur (502) zu einer Außenbegrenzung (504);

Definieren eines Brückenpunktes (506) als den Schnittpunkt jeder Brücke (500) mit der Außenbegrenzung (504);

Definieren der maximalen Anzahl von Schleifen als die Länge der längsten Brücke geteilt durch die minimale Zustellung:
Definieren der minimalen Anzahl von Schleifen als die Länge der kürzesten Brücke geteilt durch die maximale Zustellung:

Berechnen für jeden möglichen Wert der Anzahl von Schleifen zwischen der maximalen und der minimalen Anzahl von Schleifen einer ersten Bearbeitungszeit, die benötigt wird, um den Bereich zwischen Außenbegrenzung (504) und Innenkontur (502) maschinell zu bearbeiten, indem die Zeit, die benötigt wird, um das spiralförmige Werkzeugwegsegment maschinell zu bearbeiten, und die Zeit, die benötigt wird, um jeden Teil des Bereichs maschinell zu bearbeiten, der nicht durch den berechneten spiralförmigen Werkzeugweg maschinell bearbeitet werden kann, addiert werden;

Auswählen der optimalen Anzahl von Schleifen des spiralförmigen Werkzeugwegsegments als den Wert, für den die erste berechnete Bearbeitungszeit am kürzesten ist; und

wobei der tatsächliche Weg des spiralförmigen Werkzeugwegsegments wie folgt berechnet wird:

Auswählen des Brückenpunktes (510) einer ersten Brücke (512) als einen ersten Spiralpunkt eines spiralförmigen Werkzeugwegsegments (514), wobei die erste Brücke (512) ausgewählt wird, um die Zeit zu minimieren, die erforderlich ist, um das Schneidwerkzeug aus seiner vorherigen Position zu bewegen;

Berechnen eines möglichen zweiten Spiralpunktes des spiralförmigen Werkzeugwegsegments (514) als einen Punkt auf einer zweiten Brücke (516), die in einer Steigrichtung des Schneidwerkzeugs von der ersten Brücke (512) unmittelbar an die erste Brücke (512) angrenzt, wobei der Punkt von dem Brückenpunkt (517) der zweiten Brücke (516) durch die Länge der zweiten Brücke (516) geteilt durch die verbleibende Anzahl von Schleifen, die in das Werkzeugwegsegment (514) aufgenommen werden sollen, entfernt ist;

Berechnen des Eingriffswinkels, bei dem das Schneidwerkzeug in das Material eingreifen wird, indem es dem spiralförmigen Werkzeugwegsegment (514) von dem ersten Spiralpunkt (510) zu dem möglichen zweiten Spiralpunkt folgt:

in einem Fall, in dem der berechnete Eingriffswinkel zwischen dem festgelegten minimalen und maximalen Eingriffswinkel liegt, Wählen des möglichen zweiten Spiralpunktes als den zweiten Spiralpunkt (518) und Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel kleiner als der festgelegte minimale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel größer als der festgelegte minimale Eingriffswinkel zwischen dem möglichen zweiten Spiralpunkt und einem Punkt auf der zweiten Brücke ist, der von dem Brückenpunkt durch die maximale Zustellung entfernt ist; sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel größer als der festgelegte maximale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel kleiner als der festgelegte maximale Eingriffswinkel zwischen dem Brückenpunkt (517) der zweiten Brücke (516) und dem möglichen zweiten Spiralpunkt ist: sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem sich der neue lineare Nachfolger (520) mit der Innenkontur (502) des Bereichs schneidet, Beenden des spiralförmigen Werkzeugwegsegments (514) an dem Schnittpunkt;

sobald der zweite Spiralpunkt (518) berechnet worden ist, Aktualisieren der verbleibenden Anzahl von Schleifen, die in das restliche Werkzeugwegsegment (514) einzubeziehen sind; rekursives Berechnen der nachfolgenden Segmente des restlichen spiralförmigen Werkzeugwegsegments (514), wobei als erster Punkt der zweite Spiralpunkt genommen wird.


 
2. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 1 und wobei das Verfahren mindestens eine der folgenden vier Gruppen von Schritten umfasst:

die Schritte zum:

Identifizieren mindestens eines halboffenen Bereichs, für den eine erste maschinelle Bearbeitungszeit, die zum Entfernen des mindestens einen halboffenen Bereichs durch Verwendung eines trochoidalartigen Werkzeugwegs benötigt wird, länger ist als eine zweite maschinelle Bearbeitungszeit, die zum Isolieren des mindestens einen halboffenen Bereichs durch Entfernen von Trennkanälen zwischen dem mindestens einen halboffenen Bereich und allen geschlossenen Außenbegrenzungssegmenten des mindestens einen halboffenen Bereichs und Entfernen des Rests des mindestens einen halboffenen Bereichs benötigt wird; und

Definieren in dem mindestens einen zu entfernenden halboffenen Bereich mindestens eines Trennkanals zwischen dem mindestens einen halboffenen Bereich und allen geschlossenen Außenbegrenzungssegmenten des mindestens einen halboffenen Bereichs, wodurch ein verbleibender zu entfernender offener Bereich definiert wird;

die Schritte zum:

Auswählen eines Bereichs des Werkstücks, der durch das rotierende Schneidwerkzeug entfernt werden soll;

Auswählen eines ersten Teils des Bereichs des Werkstücks, der durch einen asymmetrischen spiralförmigen Werkzeugweg entfernt werden soll; und

Konfigurieren mindestens eines trochoidalartigen Werkzeugwegs zum Entfernen eines verbleibenden Teils des Bereichs des Werkstücks;

wobei das Auswählen eines ersten Teils des Bereichs dazu dient, eine zum Entfernen des Bereichs des Werkstücks benötigte maschinelle Bearbeitungszeit zu minimieren;

die Schritte zum:

unter Berücksichtigung eines Querschnitts des aus dem Werkstück herzustellenden Objekts;

Definieren isolierter Bereiche des Querschnitts auf einer Oberfläche des Werkstücks, die nicht als Inseln zu entfernen sind;

Beginnen des Konfigurierens eines Werkzeugwegs in einem Bereich, der keine Inseln hat; und

wenn der Werkzeugweg auf eine Insel trifft, Konfigurieren eines Graben-Werkzeugwegs, der einen die Insel umgebenden Graben definiert; und

die Schritte zum:

Identifizieren mindestens eines offenen Bereichs, für den eine erste maschinelle Bearbeitungszeit, die zum Entfernen des mindestens einen offenen Bereichs benötigt wird, länger ist als eine zweite maschinelle Bearbeitungszeit, die zum Aufteilen des mindestens einen offenen Bereichs in zwei unabhängige Bereiche durch Entfernen eines Trennkanals durch das rotierende Schneidwerkzeug zwischen den beiden unabhängigen Bereichen und Entfernen der beiden unabhängigen Bereiche benötigt wird; und

Definieren in dem mindestens einen offenen Bereich mindestens eines Trennkanals, der sich zwischen zwei Punkten an Kanten einer Außenbegrenzung des mindestens einen offenen Bereichs erstreckt, wodurch der mindestens eine offene Bereich in mindestens zwei unabhängige Bereiche aufgeteilt wird.


 
3. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 2 und wobei das Verfahren mindestens zwei der vier Gruppen von Schritten umfasst.
 
4. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 1 bis 3 und wobei als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks das Konfigurieren eines Werkzeugwegs auch mindestens eines des Folgenden umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels;

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug; und

Minimieren der Kosten für die Herstellung des Objekts, wobei die Kosten eine Kombination aus den Kosten für den Betrieb der Maschine während der Dauer der Herstellung und den Kosten für den Verschleiß des rotierenden Schneidwerkzeugs während der Herstellung sind.


 
5. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 1 bis 4 und wobei:

der Werkzeugweg eine Vielzahl von Werkzeugwegsegmenten umfasst; und

das Konfigurieren eines Werkzeugwegs ein rekursives Konfigurieren jedes der Werkzeugwegsegmente umfasst; und

als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks das Konfigurieren der Werkzeugwegsegmente auch Folgendes umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels; und

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug.


 
6. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 5 und wobei:

jedes der Werkzeugwegsegmente eine Vielzahl von Werkzeugweguntersegmenten umfasst; und

das rekursive Konfigurieren jedes der Werkzeugwegsegmente ein rekursives Konfigurieren jedes der Werkzeugweguntersegmente umfasst; und

als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks das Konfigurieren jedes der Werkzeugweguntersegmente auch mindestens eines von Folgendem umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels; und

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug.


 
7. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 2 bis 6 und wobei:

der asymmetrische spiralförmige Werkzeugweg eine Vielzahl von spiralförmigen Werkzeugwegsegmenten umfasst; und

der mindestens eine trochoidalartige Werkzeugweg eine Vielzahl von trochoidalartigen Werkzeugwegsegmenten umfasst; und

das Konfigurieren eines asymmetrischen sprialförmigen Werkzeugwegs ein rekursives Konfigurieren jedes der spiralförmigen Werkzeugwegsegmente umfasst; und

das Konfigurieren mindestens eines trochoidalartigen Werkzeugwegs ein rekursives Konfigurieren jedes der trochoidalartigen Werkzeugwegsegmente umfasst.


 
8. Automatisiertes computerimplementiertes Verfahren zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 2 bis 7 und das ferner die folgenden Schritte umfasst:

Definieren eines zusammengesetzten Bereichs einschließlich der Insel, des Grabens, der die Insel umgibt, und der Bereiche, die bereits von dem Werkstück entfernt wurden, als ein entfernter Bereich; und

Konfigurieren eines Werkzeugwegs zum Entfernen eines verbleibenden Bereichs des Werkstücks, wobei der verbleibende Bereich nicht den entfernten Bereich umfasst.


 
9. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück, wobei die Vorrichtung Folgendes umfasst:
eine Werkzeugwegkonfigurationsmaschine, die zum Auswählen eines Bereichs des Werkstücks, der durch ein rotierendes Schneidwerkzeug entfernt werden soll, und zur Kombination von Folgendem dient:

Konfigurieren eines Werkzeugwegs für das rotierende Schneidwerkzeug relativ zu dem Werkstück, bei dem ein Eingriffswinkel allmählich zwischen einem vorgewählten maximal zulässigen Eingriffswinkel und einem vorgewählten minimal zulässigen Eingriffswinkel variiert; und

Konfigurieren eines asymmetrischen, konvergierenden, spiralförmigen Werkzeugwegs, der eine Vielzahl von Schleifen für das rotierende Schneidwerkzeug in dem Bereich des Werkstücks umfasst, wobei der asymmetrische spiralförmige Werkzeugweg einen Teil des Bereichs des Werkstücks maximiert, der durch das rotierende Schneidwerkzeug, das sich entlang des asymmetrischen spiralförmigen Werkzeugwegs bewegt, entfernt wird;

wobei der Eingriffswinkel variiert, um dadurch den Abstand zwischen aufeinanderfolgenden Schleifen mehrmals über den Verlauf des Werkzeugweges zu variieren, um es dem Werkzeugweg zu ermöglichen, sich zwischen zwei unterschiedlichen geometrischen Formen zu wandeln;

wobei die Vorrichtung konfiguriert ist, um eine Anzahl von Schleifen, die in das konvergierende spiralförmige Werkzeugwegsegment einzubeziehen sind, durch die folgenden Schritte zu berechnen:

Definieren einer Vielzahl von Brücken (500) mit einer vordefinierten Dichte von einer Innenkontur (502) zu einer Außenbegrenzung (504);

Definieren eines Brückenpunktes (506) als den Schnittpunkt jeder Brücke (500) mit der Außenbegrenzung (504);

Definieren der maximalen Anzahl von Schleifen als die Länge der längsten Brücke geteilt durch die minimale Zustellung:
Definieren der minimalen Anzahl von Schleifen als die Länge der kürzesten Brücke geteilt durch die maximale Zustellung:

Berechnen für jeden möglichen Wert der Anzahl von Schleifen zwischen der maximalen und der minimalen Anzahl von Schleifen einer ersten Bearbeitungszeit, die benötigt wird, um den Bereich zwischen Außenbegrenzung (504) und Innenkontur (502) maschinell zu bearbeiten, indem die Zeit, die benötigt wird, um das spiralförmige Werkzeugwegsegment maschinell zu bearbeiten, und die Zeit, die benötigt wird, um jeden Teil des Bereichs maschinell zu bearbeiten, der nicht durch den berechneten spiralförmigen Werkzeugweg maschinell bearbeitet werden kann, addiert werden;

Auswählen der optimalen Anzahl von Schleifen des spiralförmigen Werkzeugwegsegments als den Wert, für den die erste berechnete Bearbeitungszeit am kürzesten ist; und

wobei die Vorrichtung konfiguriert ist, um den tatsächlichen Weg des spiralförmigen Werkzeugwegsegments wie folgt zu berechnen:

Auswählen des Brückenpunktes (510) einer ersten Brücke (512) als einen ersten Spiralpunkt eines spiralförmigen Werkzeugwegsegments (514), wobei die erste Brücke (512) ausgewählt wird, um die Zeit zu minimieren, die erforderlich ist, um das Schneidwerkzeug aus seiner vorherigen Position zu bewegen;

Berechnen eines möglichen zweiten Spiralpunktes des spiralförmigen Werkzeugwegsegments (514) als einen Punkt auf einer zweiten Brücke (516), die in einer Steigrichtung des Schneidwerkzeugs von der ersten Brücke (512) unmittelbar an die erste Brücke (512) angrenzt, wobei der Punkt von dem Brückenpunkt (517) der zweiten Brücke (516) um die Länge der zweiten Brücke (516) geteilt durch die verbleibende Anzahl von Schleifen, die in das Werkzeugwegsegment (514) aufgenommen werden sollen, entfernt ist;

Berechnen des Eingriffswinkels, bei dem das Schneidwerkzeug in das Material eingreifen wird, indem es dem spiralförmigen Werkzeugwegsegment (514) von dem ersten Spiralpunkt (510) zu dem möglichen zweiten Spiralpunkt folgt:

in einem Fall, in dem der berechnete Eingriffswinkel zwischen dem festgelegten minimalen und maximalen Eingriffswinkel liegt, Wählen des möglichen zweiten Spiralpunktes als den zweiten Spiralpunkt (518) und Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel kleiner als der festgelegte minimale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel größer als der festgelegte minimale Eingriffswinkel zwischen dem möglichen zweiten Spiralpunkt und einem Punkt auf der zweiten Brücke ist, der von dem Brückenpunkt durch die maximale Zustellung entfernt ist; sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel größer als der festgelegte maximale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel kleiner als der festgelegte maximale Eingriffswinkel zwischen dem Brückenpunkt (517) der zweiten Brücke (516) und dem möglichen zweiten Spiralpunkt ist: sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem sich der neue lineare Nachfolger (520) mit der Innenkontur (502) des Bereichs schneidet, Beenden des spiralförmigen Werkzeugwegsegments (514) an dem Schnittpunkt;

sobald der zweite Spiralpunkt (518) berechnet worden ist, Aktualisieren der verbleibenden Anzahl von Schleifen, die in das restliche Werkzeugwegsegment (514) einzubeziehen sind; rekursives Berechnen der nachfolgenden Segmente des restlichen spiralförmigen Werkzeugwegsegments (514), wobei als erster Punkt der zweite Spiralpunkt genommen wird.


 
10. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 9 und wobei das Verfahren mindestens eine der folgenden Kombinationen umfasst:

die Kombination aus:

Identifizieren von mindestens einem halboffenen Bereich, für den eine erste maschinelle Bearbeitungszeit, die zum Entfernen des mindestens einen halboffenen Bereichs durch Verwendung eines trochoidalartigen Werkzeugwegs benötigt wird, länger ist als eine zweite maschinelle Bearbeitungszeit, die zum Isolieren des mindestens einen halboffenen Bereichs durch Entfernen von Trennkanälen zwischen dem mindestens einen halboffenen Bereich und allen geschlossenen Außenbegrenzungssegmenten des mindestens einen halboffenen Bereichs und Entfernen des Rests des mindestens einen halboffenen Bereichs benötigt wird; und

Definieren in dem mindestens einen zu entfernenden halboffenen Bereich mindestens eines Trennkanals zwischen dem mindestens einen halboffenen Bereich und allen geschlossenen Außenbegrenzungssegmenten des mindestens einen halboffenen Bereichs, wodurch ein verbleibender zu entfernender offener Bereich definiert wird;

die Kombination aus:

Auswählen eines ersten Teils des Bereichs des Werkstücks, der durch einen asymmetrischen spiralförmigen Werkzeugweg entfernt werden soll; und

Konfigurieren von mindestens einem trochoidalartigen Werkzeugweg zum Entfernen eines verbleibenden Teils des Bereichs des Werkstücks, wobei das Auswählen eines ersten Teils des Bereichs des Werkstücks dazu dient, die zum Entfernen des Bereichs des Werkstücks erforderliche maschinelle Bearbeitungszeit zu minimieren;

die Kombination aus:

unter Berücksichtigung eines Querschnitts des aus dem Werkstück herzustellenden Objekts;

Definieren isolierter Bereiche des Querschnitts auf einer Oberfläche des Werkstücks, die nicht als Inseln zu entfernen sind;

Beginnen des Konfigurierens eines Werkzeugwegs in einem Bereich, der keine Inseln hat; und

wenn der Werkzeugweg auf eine Insel trifft, Konfigurieren eines Graben-Werkzeugwegs, der einen die Insel umgebenden Graben definiert; und

die Kombination aus:

Identifizieren mindestens eines offenen Bereichs, für den eine erste maschinelle Bearbeitungszeit, die zum Entfernen des mindestens einen offenen Bereichs benötigt wird, länger ist als eine zweite maschinelle Bearbeitungszeit, die zum Aufteilen des mindestens einen offenen Bereichs in zwei unabhängige Bereiche durch Entfernen eines Trennkanals durch das rotierende Schneidwerkzeug zwischen den zwei unabhängigen Bereichen und Entfernen der zwei unabhängigen Bereiche benötigt wird; und

Definieren in dem mindestens einen offenen Bereich mindestens eines Trennkanals, der sich zwischen zwei Punkten an Kanten einer Außengrenze des mindestens einen offenen Bereichs erstreckt, wodurch der mindestens eine offene Bereich in mindestens zwei unabhängige Bereiche aufgeteilt wird.


 
11. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 10 und wobei als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks und des Konfigurierens jedes der Werkzeugwegsegmente das Konfigurieren eines Werkzeugwegs mindestens eines des Folgenden umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels;

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug; und

Minimieren der Kosten für die Herstellung des Objekts, wobei die Kosten eine Kombination aus den Kosten für den Betrieb der Maschine während der Dauer der Herstellung und den Kosten für den Verschleiß des rotierenden Schneidwerkzeugs während der Herstellung sind.


 
12. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 9 bis 11 und wobei:

der Werkzeugweg eine Vielzahl von Werkzeugwegsegmenten umfasst; und

das Konfigurieren eines Werkzeugwegs ein rekursives Konfigurieren jedes der Werkzeugwegsegmente umfasst; und

als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks, des Konfigurierens jedes der Werkzeugwegsegmente das Konfigurieren jedes der Werkzeugwegsegmente auch mindestens eines von Folgendem umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels; und

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug.


 
13. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach Anspruch 12 und wobei:

jedes der Werkzeugwegsegmente eine Vielzahl von Werkzeugweguntersegmenten umfasst; und

das rekursive Konfigurieren jedes der Werkzeugwegsegmente ein rekursives Konfigurieren jedes der Werkzeugweguntersegmente umfasst; und

als Reaktion auf die Berücksichtigung von mindestens einer der Eigenschaften der numerischen gesteuerten Computermaschine, des rotierenden Schneidwerkzeugs und des Materials des Werkstücks, des Konfigurierens jedes der Werkzeugwegsegmente das Konfigurieren jedes der Werkzeugweguntersegmente auch mindestens eines von Folgendem umfasst:

Minimieren, vorbehaltlich anderer Einschränkungen, einer Änderungsrate des Eingriffswinkels im Laufe der Zeit;

allmähliches Ändern einer Vorschubgeschwindigkeit des rotierenden Schneidwerkzeugs gemäß Änderungen des Eingriffswinkels; und

Aufrechterhalten einer allgemein konstanten Arbeitslast auf das rotierende Schneidwerkzeug.


 
14. Automatisierte Vorrichtung zum Erzeugen von Befehlen zum Steuern einer numerischen gesteuerten Computermaschine zur Herstellung eines Objekts aus einem Werkstück nach einem der Ansprüche 10 bis 13 und wobei die Konfigurationsmaschine auch für Folgendes betriebsfähig ist:

Definieren eines zusammengesetzten Bereichs einschließlich der Insel, des Grabens, der die Insel umgibt, und der Bereiche, die bereits von dem Werkstück entfernt wurden, als einen entfernten Bereich; und

Konfigurieren eines Werkzeugwegs zum Entfernen eines verbleibenden Bereichs des Werkstücks, wobei der verbleibende Bereich nicht den entfernten Bereich umfasst.


 
15. Automatisierte computergesteuerte Maschine, um ein Objekt aus einem Werkstück herzustellen, wobei die Maschine Folgendes umfasst:
eine Steuerung, die zum Auswählen eines Bereichs des Werkstücks, der durch ein rotierendes Schneidwerkzeug entfernt werden soll, und zu Folgendem dient:
die Kombination aus:

Lenken des rotierenden Schneidwerkzeugs entlang eines asymmetrischen, konvergierenden, spiralförmigen Werkzeugwegs, der eine Vielzahl von Schleifen in dem Bereich des Werkstücks umfasst, wobei der spiralförmige Werkzeugweg einen Teil des Bereichs des Werkstücks maximiert, der durch das rotierende Schneidwerkzeug, das sich entlang des asymmetrischen, spiralförmigen Werkzeugwegs bewegt, entfernt wird;

Lenken des rotierenden Schneidwerkzeugs entlang eines Werkzeugwegs relativ zu dem Werkstück, bei dem ein Eingriffswinkel zwischen dem rotierenden Schneidwerkzeug und dem Werkstück allmählich zwischen einem vorausgewählten maximal zulässigen Eingriffswinkel und einem vorausgewählten minimal zulässigen Eingriffswinkel variiert;

wobei der Eingriffswinkel variiert, um dadurch den Abstand zwischen aufeinanderfolgenden Schleifen mehrmals über den Verlauf des Werkzeugwegs zu variieren, um es dem Werkzeugweg zu ermöglichen, sich zwischen zwei unterschiedlichen geometrischen Formen zu wandeln;

wobei die Steuerung konfiguriert ist, um eine Anzahl von Schleifen, die in das konvergierende spiralförmige Werkzeugwegsegment einzubeziehen sind, durch die folgenden Schritte zu berechnen:

Definieren einer Vielzahl von Brücken (500) mit einer vordefinierten Dichte von einer Innenkontur (502) zu einer Außenbegrenzung (504);

Definieren eines Brückenpunktes (506) als den Schnittpunkt jeder Brücke (500) mit der Außenbegrenzung (504);

Definieren der maximalen Anzahl von Schleifen als die Länge der längsten Brücke geteilt durch die minimale Zustellung:

Definieren der minimalen Anzahl von Schleifen als die Länge der kürzesten Brücke geteilt durch die maximale Zustellung:

Berechnen für jeden möglichen Wert der Anzahl von Schleifen zwischen der maximalen und der minimalen Anzahl von Schleifen einer ersten Bearbeitungszeit, die benötigt wird, um den Bereich zwischen Außenbegrenzung (504) und Innenkontur (502) maschinell zu bearbeiten, indem die Zeit, die benötigt wird, um das spiralförmige Werkzeugwegsegment maschinell zu bearbeiten, und die Zeit, die benötigt wird, um jeden Teil des Bereichs maschinell zu bearbeiten, der nicht durch den berechneten spiralförmigen Werkzeugweg maschinell bearbeitet werden kann, addiert werden;

Auswählen der optimalen Anzahl von Schleifen des spiralförmigen Werkzeugwegsegments als den Wert, für den die erste berechnete Bearbeitungszeit am kürzesten ist; und

wobei die Steuerung konfiguriert ist, um den tatsächlichen Weg des spiralförmigen Werkzeugwegsegments wie folgt zu berechnen:

Auswählen des Brückenpunktes (510) einer ersten Brücke (512) als einen ersten Spiralpunkt des spiralförmigen Werkzeugwegsegments (514), wobei die erste Brücke (512) ausgewählt wird, um die Zeit zu minimieren, die erforderlich ist, um das Schneidwerkzeug aus seiner vorherigen Position zu bewegen;

Berechnen eines möglichen zweiten Spiralpunktes des spiralförmigen Werkzeugwegsegments (514) als einen Punkt auf einer zweiten Brücke (516), die in einer Steigrichtung des Schneidwerkzeugs von der ersten Brücke (512) unmittelbar an die erste Brücke (512) angrenzt, wobei der Punkt von dem Brückenpunkt (517) der zweiten Brücke (516) um die Länge der zweiten Brücke (516) geteilt durch die verbleibende Anzahl von Schleifen, die in das Werkzeugwegsegment (514) aufgenommen werden sollen, entfernt ist;

Berechnen des Eingriffswinkels, bei dem das Schneidwerkzeug in das Material eingreifen wird, indem es dem spiralförmigen Werkzeugwegsegment (514) von dem ersten Spiralpunkt (510) zu dem möglichen zweiten Spiralpunkt folgt:

in einem Fall, in dem der berechnete Eingriffswinkel zwischen dem festgelegten minimalen und maximalen Eingriffswinkel liegt, Wählen des möglichen zweiten Spiralpunktes als den zweiten Spiralpunkt (518) und Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel kleiner als der festgelegte minimale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel größer als der festgelegte minimale Eingriffswinkel zwischen dem möglichen zweiten Spiralpunkt und einem Punkt auf der zweiten Brücke ist, der von dem Brückenpunkt durch die maximale Zustellung entfernt ist; sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem der Eingriffswinkel größer als der festgelegte maximale Eingriffswinkel ist, Durchführen einer binären Suche nach einem zweiten Spiralpunkt, für den der berechnete Eingriffswinkel kleiner als der festgelegte maximale Eingriffswinkel zwischen dem Brückenpunkt (517) der zweiten Brücke (516) und dem möglichen zweiten Spiralpunkt ist: sobald ein zweiter Spiralpunkt (518) gefunden ist, Hinzufügen eines neuen linearen Nachfolgers (520) zwischen dem ersten Spiralpunkt (510) und dem zweiten Spiralpunkt (518) zu dem spiralförmigen Werkzeugwegsegment (514);

in einem Fall, in dem sich der neue lineare Nachfolger (520) mit der Innenkontur (502) des Bereichs schneidet, Beenden des spiralförmigen Werkzeugwegsegments (514) an dem Schnittpunkt;

sobald der zweite Spiralpunkt (518) berechnet worden ist, Aktualisieren der verbleibenden Anzahl von Schleifen, die in das restliche Werkzeugwegsegment (514) einzubeziehen sind; rekursives Berechnen der nachfolgenden Segmente des restlichen spiralförmigen Werkzeugwegsegments (514), wobei als erster Punkt der zweite Spiralpunkt genommen wird.


 
16. Verfahren zur maschinellen Bearbeitung eines Werkstücks unter Einsatz einer computergesteuerten Werkzeugmaschine, wobei das Verfahren Folgendes umfasst:

Auswählen des Bereichs des Werkstücks, der durch ein rotierendes Schneidwerkzeug entfernt werden soll;

Erzeugen von Befehlen nach einem der Ansprüche 1 bis 8; und

Lenken des rotierenden Schneidwerkzeugs unter Verwendung der erzeugten Befehle entlang eines asymmetrischen, spiralförmigen Werkzeugwegs, der eine Vielzahl von Schleifen in dem Bereich des Werkstücks umfaßt, wobei der spiralförmige Werkzeugweg einen Teil des Bereichs des Werkstücks maximiert, der durch das rotierende Schneidwerkzeug, das sich entlang des asymmetrischen, spiralförmigen Werkzeugwegs bewegt, entfernt wird;

wobei ein Eingriffswinkel zwischen dem rotierenden Schneidwerkzeug und dem Werkstück allmählich zwischen einem vorgewählten maximal zulässigen Eingriffswinkel und einem vorgewählten minimal zulässigen Eingriffswinkel variiert;

wobei der Eingriffswinkel variiert, um dadurch den Abstand zwischen aufeinanderfolgenden Schleifen mehrmals über den Verlauf des Werkzeugwegs zu variieren, um es dem Werkzeugweg zu ermöglichen, sich zwischen zwei unterschiedlichen geometrischen Formen zu wandeln.


 


Revendications

1. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication, le procédé comprenant les deux groupes d'étapes suivants :
les étapes de :

sélectionner un angle d'engagement maximum autorisé entre un outil de coupe rotatif et ladite pièce de fabrication ;

sélectionner un angle d'engagement minimum autorisé entre ledit outil de coupe rotatif et ladite pièce de fabrication ; et

configurer une trajectoire d'outil pour ledit outil de coupe rotatif par rapport à ladite pièce de fabrication dans laquelle un angle d'engagement entre ledit outil de coupe rotatif et ladite pièce de fabrication varie progressivement entre ledit angle d'engagement maximal autorisé et ledit angle d'engagement minimal autorisé ; et

les étapes de :

sélectionner une région de ladite pièce de fabrication à retirer par ledit outil de coupe rotatif ; et

configurer une trajectoire d'outil en spirale convergente asymétrique comprenant une pluralité de boucles pour ledit outil de coupe rotatif dans ladite région de ladite pièce de fabrication, laquelle trajectoire d'outil en spirale asymétrique maximise une partie de ladite région de ladite pièce de fabrication qui est retirée par ledit outil de coupe rotatif se déplaçant le long de ladite trajectoire d'outil en spirale asymétrique ;

dans lequel l'angle d'engagement varie pour ainsi faire varier la distance entre les boucles séquentielles plusieurs fois au cours de la trajectoire d'outil pour permettre à la trajectoire d'outil de se transformer entre deux formes géométriques différentes ;

dans lequel un certain nombre de boucles à inclure dans le segment de trajectoire d'outil en spirale convergente est calculé par les étapes suivantes :

définir une pluralité de ponts (500) d'une densité prédéfinie depuis un contour interne (502) jusqu'à une limite externe (504) ;

définir un point de pont (506) comme le point d'intersection de chaque pont (500) avec la limite externe (504) ;

définir le nombre maximal de boucles comme la longueur du pont le plus long divisé par le pas minimal ;

définir le nombre minimal de boucles comme la longueur du pont le plus court divisé par le pas maximal ;

calculer pour chaque valeur possible du nombre de boucles entre le nombre maximum et le nombre minimum de boucles, un premier temps de travail nécessaire pour usiner la zone entre la limite externe (504) et le contour interne (502) en additionnant le temps nécessaire pour usiner le segment de trajectoire d'outil en spirale et le temps nécessaire pour usiner toute partie de la région qui ne peut pas être usinée par la trajectoire d'outil en spirale calculée ;

sélectionner le nombre optimal de boucles du segment de trajectoire d'outil en spirale comme valeur pour laquelle le premier temps de travail calculé est le plus court ; et

dans lequel la trajectoire réelle du segment de trajectoire d'outil en spirale est calculée comme suit :

sélectionner le point de pont (510) d'un premier pont (512) en tant que premier point en spirale du segment de trajectoire d'outil en spirale (514), dans lequel le premier pont (512) est sélectionné pour minimiser le temps nécessaire pour déplacer l'outil de coupe de sa position précédente ;

calculer un deuxième point de spirale possible du segment de trajectoire d'outil en spirale (514) comme un point sur un deuxième pont (516), immédiatement adjacent au premier pont (512) dans une direction de montée de l'outil de coupe à partir du premier pont (512), ledit point est éloigné du point de pont (517) du deuxième pont (516) par la longueur du deuxième pont (516) divisée par le nombre restant de boucles à inclure dans le segment de trajectoire d'outil (514) ;

calculer l'angle d'engagement auquel l'outil de coupe va engager le matériau en suivant le segment de trajectoire d'outil en spirale (514) du premier point en spirale (510) au deuxième point en spirale possible :

dans un cas où l'angle d'engagement calculé est compris entre les angles d'engagement minimum et maximum prédéterminés, choisir le deuxième point en spirale possible comme deuxième point en spirale (518) et ajouter une nouvelle séquence linéaire (520) entre le premier point en spirale (510) et un deuxième point en spirale (518) vers le segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est inférieur à l'angle d'engagement minimum prédéterminé, effectuer une recherche binaire pour un deuxième point de spirale pour lequel l'angle d'engagement calculé est supérieur à l'angle d'engagement minimum prédéterminé entre le deuxième point de spirale possible et un point sur le deuxième pont éloigné du point de pont par le pas maximal ; une fois qu'un deuxième point en spirale (518) est trouvé, ajouter une nouvelle séquence linéaire suivante (520) entre le premier point en spirale (510) et le deuxième point en spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est supérieur à l'angle d'engagement maximum prédéterminé, effectuer une recherche binaire d'un deuxième point en spirale pour lequel l'angle d'engagement calculé est inférieur à l'angle d'engagement maximum prédéterminé entre le point de pont (517) du deuxième pont (516) et le deuxième point en spirale possible : une fois qu'un deuxième point en spirale (518) est trouvé, l'ajout d'une nouvelle séquence linéaire suivant (520) entre le premier point en spirale (510) et le deuxième point en spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où la nouvelle séquence linéaire (520) coupe le contour interne (502) de la région, terminant le segment de trajectoire d'outil en spirale (514) au point d'intersection ;

une fois que le deuxième point en spirale (518) a été calculé, mettre à jour le nombre restant de boucles à inclure dans le reste du segment de trajectoire d'outil (514) ; calculer récursivement les segments suivants du reste du segment de trajectoire d'outil en spirale (514) en prenant comme premier point le deuxième point en spirale.


 
2. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 1 et dans lequel le procédé comprend au moins l'un des quatre groupes d'étapes suivants :
les étapes de :

identifier au moins une région semi-ouverte pour laquelle un premier temps d'usinage nécessaire pour retirer ladite au moins une région semi-ouverte en utilisant une trajectoire d'outil de type trochoïdal est plus long qu'un second temps d'usinage nécessaire pour isoler ladite au moins une semi-ouverte région en supprimant les canaux de séparation entre ladite au moins une région semi-ouverte et tous les segments de limite externe fermés de ladite au moins une région semi-ouverte et en retirant le reste de ladite au moins une région semi-ouverte ; et

définir dans ladite au moins une région semi-ouverte à retirer au moins un canal de séparation entre ladite au moins une région semi-ouverte et tous les segments de limite externes fermés de ladite au moins une région semi-ouverte, définissant ainsi une région ouverte restante à être retiré ;

les étapes de :

sélectionner une région de ladite pièce de fabrication à retirer par ledit outil de coupe rotatif ;

sélectionner une première partie de ladite région de ladite pièce de fabrication à retirer par une trajectoire d'outil en spirale asymétrique ; et

configurer au moins une trajectoire d'outil de type trochoïdal pour retirer une partie restante de ladite région de ladite pièce de fabrication ;

dans lequel ladite sélection d'une première partie de ladite région est opérationnelle pour minimiser un temps d'usinage nécessaire pour retirer ladite région de ladite pièce de fabrication ;

les étapes de :

considérer une section transversale dudit objet à fabriquer à partir de ladite pièce de fabrication ;

définir des régions isolées de ladite section transversale sur une surface de ladite pièce de fabrication qui ne doivent pas être retirées en tant qu'îlots ;

commencer la configuration d'une trajectoire d'outil dans une région sans îlots ; et

lorsque ladite trajectoire d'outil rencontre un îlot, configurer une trajectoire d'outil en fossé qui définit un fossé entourant ledit îlot ; et

les étapes de :

identifier au moins une région ouverte pour laquelle un premier temps d'usinage nécessaire pour retirer ladite au moins une région ouverte est plus long qu'un deuxième temps d'usinage nécessaire pour diviser ladite au moins une région ouverte en deux régions indépendantes en supprimant un canal de séparation par ledit outil de coupe rotatif entre lesdites deux régions indépendantes et retirer lesdites deux régions indépendantes ; et

définir dans ladite au moins une région ouverte au moins un canal de séparation s'étendant entre deux points sur les bords d'une limite externe de ladite au moins une région ouverte, divisant ainsi ladite au moins une région ouverte en au moins deux régions indépendantes.


 
3. Procédé automatisé implémenté par ordinateur pour générer des commandes pour commander une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 2 et dans lequel le procédé comprend au moins deux desdits quatre groupes d'étapes.
 
4. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon l'une quelconque des revendications 1 à 3 et dans lequel en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, ledit outil de coupe rotatif et le matériau de ladite pièce de fabrication, ladite configuration d'une trajectoire d'outil comprend également au moins l'un des éléments suivants :

minimiser, sous réserve d'autres contraintes, une vitesse de changement dudit angle d'engagement dans le temps ;

changer progressivement une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ;

maintenir une charge de travail généralement constante sur ledit outil de coupe rotatif ; et

minimiser un coût de fabrication dudit objet, ledit coût étant une combinaison d'un coût de fonctionnement de ladite machine pendant la durée de ladite fabrication et d'un coût d'usure infligé audit outil de coupe rotatif pendant ladite fabrication.


 
5. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon l'une quelconque des revendications 1 à 4 et dans lequel :

ladite trajectoire d'outil comprend une pluralité de segments de trajectoire d'outil ; et

ladite configuration d'une trajectoire d'outil comprend la configuration récursive de chacun desdits segments de trajectoire d'outil ; et

en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, dudit outil de coupe rotatif et du matériau de ladite pièce, ladite configuration de chacun desdits segments de trajectoire d'outil inclut également :

la minimisation, sous réserve d'autres contraintes, d'une vitesse de changement dudit angle d'engagement dans le temps ;

le changement progressif d'une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ; et

la maintenance d'une charge de travail généralement constante sur ledit outil de coupe rotatif.


 
6. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 5 et dans lequel :

chacun desdits segments de trajectoire d'outil comprend une pluralité de sous-segments de trajectoire d'outil ; et

ladite configuration récursive de chacun desdits segments de trajectoire d'outil comprend la configuration récursive de chacun desdits sous-segments de trajectoire d'outil ; et

en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, dudit outil de coupe rotatif et du matériau de ladite pièce, ladite configuration de chacun desdits sous-segments de trajectoire d'outil comprend également au moins l'un des éléments suivants :

la minimisation, sous réserve d'autres contraintes, d'une vitesse de changement dudit angle d'engagement dans le temps ;

le changement progressif d'une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ; et

la maintenance d'une charge de travail généralement constante sur ledit outil de coupe rotatif.


 
7. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon l'une quelconque des revendications 2 à 6 et dans lequel :

ladite trajectoire d'outil en spirale asymétrique comprend une pluralité de segments de trajectoire d'outil en spirale ;

ladite au moins une trajectoire d'outil de type trochoïdal comprend une pluralité de segments de trajectoire d'outil de type trochoïdal ;

ladite configuration d'une trajectoire d'outil en spirale asymétrique comprend la configuration récursive de chacun desdits segments de trajectoire d'outil en spirale ; et

ladite configuration d'au moins une trajectoire d'outil de type trochoïdal comprend la configuration récursive de chacun desdits segments de trajectoire d'outil de type trochoïdal.


 
8. Procédé automatisé implémenté par ordinateur pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon l'une quelconque des revendications 2 à 7 et comprenant en outre les étapes de :

définir une région composite comprenant ledit îlot, ledit fossé entourant ledit îlot et les régions déjà retirées de ladite pièce de fabrication en tant que région retirée ; et

configurer une trajectoire d'outil pour retirer une région restante de ladite pièce, laquelle région restante ne comprend pas ladite région retirée.


 
9. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication, l'appareil comprenant :
un moteur de configuration de trajectoire d'outil fonctionnant pour sélectionner une région de ladite pièce de fabrication à retirer par un outil de coupe rotatif et pour la combinaison de :

configurer une trajectoire d'outil pour ledit outil de coupe rotatif par rapport à ladite pièce de fabrication dans laquelle un angle d'engagement varie progressivement entre un angle d'engagement maximum présélectionné et un angle d'engagement minimum présélectionné ; et

configurer une trajectoire d'outil en spirale convergente asymétrique comprenant une pluralité de boucles pour ledit outil de coupe rotatif dans ladite région de ladite pièce de fabrication, laquelle trajectoire d'outil en spirale maximise la partie de ladite région de ladite pièce de fabrication qui est enlevée par ledit outil de coupe rotatif se déplaçant le long de ladite trajectoire d'outil en spirale asymétrique ;

dans lequel l'angle d'engagement varie pour ainsi faire varier la distance entre les boucles séquentielles plusieurs fois au cours de la trajectoire d'outil pour permettre à la trajectoire d'outil de se transformer entre deux formes géométriques différentes ;

dans lequel l'appareil est configuré pour calculer un nombre de boucles à inclure dans le segment de trajectoire d'outil en spirale convergente par les étapes suivantes :

définir une pluralité de ponts (500) d'une densité prédéfinie depuis un contour interne (502) jusqu'à une limite externe (504) ;

définir un point de pont (506) comme le point d'intersection de chaque pont (500) avec la limite externe (504) ;

définir le nombre maximal de boucles comme la longueur du pont le plus long divisé par le pas minimal ;

définir le nombre minimal de boucles comme la longueur du pont le plus court divisé par le pas maximal ;

calculer pour chaque valeur possible du nombre de boucles entre le nombre maximum et le nombre minimum de boucles, un premier temps de travail nécessaire pour usiner la zone entre la limite externe (504) et le contour interne (502) en additionnant le temps nécessaire pour usiner la spirale segment de trajectoire d'outil et temps nécessaire pour usiner toute partie de la région qui ne peut pas être usinée par la trajectoire d'outil en spirale calculée ;

sélectionner le nombre optimal de boucles du segment de trajectoire d'outil en spirale comme valeur pour laquelle le premier temps de travail calculé est le plus court ; et

dans lequel l'appareil est configuré pour calculer la trajectoire réelle du segment de trajectoire d'outil en spirale par les étapes suivantes :

sélectionner le point de pont (510) d'un premier pont (512) en tant que premier point en spirale du segment de chemin d'outil en spirale (514), dans lequel le premier pont (512) est sélectionné pour minimiser le temps nécessaire pour déplacer l'outil de coupe de sa position précédente ;

calculer un deuxième point de spirale possible du segment de trajectoire d'outil en spirale (514) comme un point sur un deuxième pont (516), immédiatement adjacent au premier pont (512) dans une direction de montée de l'outil de coupe à partir du premier pont (512), ledit point est éloigné du point de pont (517) du deuxième pont (516) par la longueur du deuxième pont (516) divisée par le nombre restant de boucles à inclure dans le segment de trajectoire d'outil (514) ;

calculer l'angle d'engagement auquel l'outil de coupe va engager le matériau en suivant le segment de trajectoire d'outil en spirale (514) du premier point en spirale (510) au deuxième point en spirale possible ;

dans un cas où l'angle d'engagement calculé est compris entre les angles d'engagement minimum et maximum prédéterminés, choisir le deuxième point en spirale possible comme deuxième point en spirale (518) et ajouter une nouvelle séquence linéaire suivante (520) entre le premier point en spirale (510) et un deuxième point en spirale (518) vers le segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est inférieur à l'angle d'engagement minimum prédéterminé, effectuer une recherche binaire pour un deuxième point en spirale pour lequel l'angle d'engagement calculé est supérieur à l'angle d'engagement minimum prédéterminé entre le deuxième point en spirale possible et un point sur le deuxième pont éloigné du point de pont par le pas maximal ; une fois qu'un deuxième point en spirale (518) a été trouvé, ajouter une nouvelle séquence linéaire (520) entre le premier point en spirale (510) et le deuxième point en spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est supérieur à l'angle d'engagement maximum prédéterminé, effectuer une recherche binaire pour un deuxième point en spirale pour lequel l'angle d'engagement calculé est inférieur à l'angle d'engagement maximum prédéterminé entre le point de pont (517) du deuxième pont (516) et le deuxième point en spirale possible ; une fois qu'un deuxième point de spirale (518) est trouvé, ajouter une nouvelle séquence linéaire (520) entre le premier point en spirale (510) et le deuxième point en spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où la nouvelle séquence linéaire (520) coupe le contour interne (502) de la région, terminer le segment de trajectoire d'outil en spirale (514) au point d'intersection ;

une fois que le deuxième point en spirale (518) a été calculé, mettre à jour le nombre restant de boucles à inclure dans le reste du segment de trajectoire d'outil (514) ; calculer récursivement les segments suivants du reste du segment de trajectoire d'outil en spirale (514) en prenant comme premier point le deuxième point en spirale.


 
10. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 9 et dans lequel le procédé comprend au moins l'une des combinaisons suivantes :
la combinaison de :

identifier au moins une région semi-ouverte pour laquelle un premier temps d'usinage nécessaire pour retirer ladite au moins une région semi-ouverte en utilisant une trajectoire d'outil de type trochoïdal est plus long qu'un deuxième temps d'usinage nécessaire pour isoler ladite au moins une région semi-ouverte en retirant les canaux de séparation entre ladite au moins une région semi-ouverte et tous les segments de limite externe fermés de ladite au moins une région semi-ouverte et en retirant le reste de ladite au moins une région semi-ouverte ; et définir dans ladite au moins une région semi-ouverte à retirer au moins un canal de séparation entre ladite au moins une région semi-ouverte et tous les segments de limite externe fermés de ladite au moins une région semi-ouverte, définissant ainsi une région ouverte restante à être retiré ;

la combinaison de :

sélectionner une première partie de ladite région de ladite pièce fabrication à retirer par une trajectoire d'outil en spirale asymétrique ; et

configurer au moins une trajectoire d'outil de type trochoïdale pour retirer une partie restante de ladite région de ladite pièce de fabrication, dans lequel ladite sélection d'une première partie de ladite région de ladite pièce de fabrication est opérationnelle pour minimiser un temps d'usinage nécessaire pour retirer ladite région de ladite pièce de fabrication ;

la combinaison de :

considérer une section transversale dudit objet à fabriquer à partir de ladite pièce de fabrication ;

définir des régions isolées de ladite section transversale sur une surface de ladite pièce de fabrication qui ne doivent pas être retirées en tant qu'îlots ;

commencer la configuration d'une trajectoire d'outil dans une région sans îlots ; et

lorsque ladite trajectoire d'outil rencontre un îlot, configurer une trajectoire d'outil de fossé qui définit un fossé entourant ledit îlot ; et

la combinaison de :

identifier au moins une région ouverte pour laquelle un premier temps d'usinage nécessaire pour retirer ladite au moins une région ouverte est plus long qu'un deuxième temps d'usinage nécessaire pour diviser ladite au moins une région ouverte en deux régions indépendantes en supprimant un canal de séparation par ledit outil de coupe rotatif entre lesdites deux régions indépendantes et retirer lesdites deux régions indépendantes ; et

définir dans ladite au moins une région ouverte au moins un canal de séparation s'étendant entre deux points sur les bords d'une limite externe de ladite au moins une région ouverte, divisant ainsi ladite au moins une région ouverte en au moins deux régions indépendantes.


 
11. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 10 et dans lequel ladite configuration d'une trajectoire d'outil comprend, en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, ledit outil de coupe rotatif et le matériau de ladite pièce, ladite configuration de chacun desdits segments de trajectoire d'outil, au moins l'un parmi :

la minimisation, sous réserve d'autres contraintes, d'une vitesse de changement dudit angle d'engagement dans le temps ;

changer progressivement une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ;

maintenir une charge de travail généralement constante sur ledit outil de coupe rotatif ; et

minimiser un coût de fabrication dudit objet, ledit coût étant une combinaison d'un coût de fonctionnement de ladite machine pendant la durée de ladite fabrication et d'un coût d'usure infligé audit outil de coupe rotatif pendant ladite fabrication.


 
12. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce selon l'une quelconque des revendications 9 à 11 et dans lequel :

ladite trajectoire d'outil comprend une pluralité de segments de trajectoire d'outil ; et

ladite configuration d'une trajectoire d'outil comprend la configuration récursive de chacun desdits segments de trajectoire d'outil ; et

ladite configuration de chacun desdits segments de trajectoire d'outil inclut également, en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, ledit outil de coupe rotatif et le matériau de ladite pièce de fabrication, ladite configuration de chacun desdits segments de trajectoire d'outil, au moins l'un parmi :

la minimisation, sous réserve d'autres contraintes, d'une vitesse de changement dudit angle d'engagement dans le temps ;

le changement progressif d'une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ; et

la maintenance d'une charge de travail généralement constante sur ledit outil de coupe rotatif.


 
13. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon la revendication 12 et dans lequel :

chacun desdits segments de trajectoire d'outil comprend une pluralité de sous-segments de trajectoire d'outil ; et

ladite configuration récursive de chacun desdits segments de trajectoire d'outil comprend la configuration récursive de chacun desdits sous-segments de trajectoire d'outil ; et

ladite configuration de chacun desdits sous-segments de trajectoire d'outil inclut également, en réponse à la considération d'au moins une des caractéristiques de ladite machine à commande numérique par ordinateur, ledit outil de coupe rotatif et le matériau de ladite pièce, ladite configuration de chacun desdits segments de trajectoire d'outil, au moins l'un parmi :

la minimisation, sous réserve d'autres contraintes, d'une vitesse de changement dudit angle d'engagement dans le temps ;

le changement progressif d'une vitesse d'entraînement dudit outil de coupe rotatif correspondant aux changements dudit angle d'engagement ; et

la maintenance d'une charge de travail généralement constante sur ledit outil de coupe rotatif.


 
14. Appareil automatisé pour générer des commandes pour contrôler une machine à commande numérique par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication selon l'une quelconque des revendications 10 à 13 et dans lequel ledit moteur de configuration fonctionne également pour :

définir une région composite comprenant ledit îlot, ledit fossé entourant ledit îlot et les régions déjà retirées de ladite pièce de fabrication en tant que région retirée ; et

configurer une trajectoire d'outil pour retirer une région restante de ladite pièce de fabrication, laquelle région restante ne comprend pas ladite région retirée.


 
15. Machine automatisée commandée par ordinateur pour fabriquer un objet à partir d'une pièce de fabrication, la machine comprenant :
un contrôleur opérationnel pour sélectionner une région de ladite pièce de fabrication à retirer par un outil de coupe rotatif ; et pour :
la combinaison de :

diriger ledit outil de coupe rotatif le long d'une trajectoire d'outil en spirale convergente asymétrique comprenant une pluralité de boucles dans ladite région de ladite pièce de fabrication, laquelle trajectoire d'outil en spirale maximise une partie de ladite région de ladite pièce de fabrication qui est retirée par ledit outil de coupe rotatif se déplaçant le long de ladite trajectoire d'outil en spirale asymétrique ;

diriger ledit outil de coupe rotatif le long d'une trajectoire d'outil par rapport à ladite pièce de fabrication dans laquelle un angle d'engagement entre ledit outil de coupe rotatif et ladite pièce de fabrication varie progressivement entre un angle d'engagement maximal autorisé présélectionné et un angle d'engagement minimal autorisé présélectionné

dans lequel l'angle d'engagement varie pour ainsi faire varier la distance entre les boucles séquentielles plusieurs fois au cours de la trajectoire d'outil pour permettre à la trajectoire d'outil de se transformer entre deux formes géométriques différentes ;

dans lequel le contrôleur est configuré pour calculer un nombre de boucles à inclure dans le segment de trajectoire d'outil en spirale convergente par les étapes suivantes :

définir une pluralité de ponts (500) d'une densité prédéfinie depuis un contour interne (502) jusqu'à une limite externe (504) ;

définir un point de pont (506) comme le point d'intersection de chaque pont (500) avec la limite extérieure (504) ;

définir le nombre maximum de boucles comme la longueur du pont le plus long divisé par le pas minimal :
définir le nombre minimum de boucles comme la longueur du pont le plus court divisé par le pas maximal :

calculer pour chaque valeur possible du nombre de boucles entre le nombre maximum et le nombre minimum de boucles, un premier temps de travail nécessaire pour usiner la zone entre la limite externe (504) et le contour interne (502) en additionnant le temps nécessaire pour usiner le segment de trajectoire d'outil en spirale et le temps nécessaire pour usiner toute partie de la région qui ne peut pas être usinée par la trajectoire d'outil en spirale calculée ;

sélectionner le nombre optimal de boucles du segment de trajectoire d'outil en spirale comme valeur pour laquelle le premier temps de travail calculé est le plus court ; et

dans lequel le contrôleur est configuré pour calculer la trajectoire réelle du segment de chemin d'outil en spirale comme suit :

sélectionner le point de pont (510) d'un premier pont (512) comme premier point en spirale du segment de chemin d'outil en spirale (514), dans lequel le premier pont (512) est sélectionné pour minimiser le temps nécessaire pour déplacer l'outil de coupe de sa position précédente ;

calculer un deuxième point en spirale possible du segment de trajectoire d'outil en spirale (514) comme un point sur un deuxième pont (516), immédiatement adjacent au premier pont (512) dans une direction de montée de l'outil de coupe à partir du premier pont (512), ledit point est éloigné du point de pont (517) du deuxième pont (516) par la longueur du deuxième pont (516) divisée par le nombre restant de boucles à inclure dans le segment de trajectoire d'outil (514) ;

calculer l'angle d'engagement auquel l'outil de coupe va engager le matériau en suivant le segment de chemin d'outil en spirale (514) du premier point en spirale (510) au deuxième point en spirale possible ;

dans un cas où l'angle d'engagement calculé est compris entre les angles d'engagement minimum et maximum prédéterminés, choisir le deuxième point de spirale possible comme deuxième point de spirale (518) et ajouter une nouvelle séquence linéaire suivante (520) entre le premier point en spirale (510) et un deuxième point en spirale (518) vers le segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est inférieur à l'angle d'engagement minimum prédéterminé, effectuer une recherche binaire pour un deuxième point de spirale pour lequel l'angle d'engagement calculé est supérieur à l'angle d'engagement minimum prédéterminé entre le deuxième point de spirale possible et un point sur le deuxième pont éloigné du point de pont par le pas maximal ; une fois qu'un deuxième point en spirale (518) a été trouvé, ajouter une nouvelle séquence linéaire (520) entre le premier point en spirale (510) et le deuxième point en spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où l'angle d'engagement est supérieur à l'angle d'engagement maximum prédéterminé, effectuer une recherche binaire d'un deuxième point en spirale pour lequel l'angle d'engagement calculé est inférieur à l'angle d'engagement maximum prédéterminé entre le point de pont (517) du deuxième pont (516) et le deuxième point en spirale possible ; une fois qu'un deuxième point de spirale (518) est trouvé, ajouter une nouvelle séquence linéaire (520) entre le premier point de spirale (510) et le deuxième point de spirale (518) au segment de trajectoire d'outil en spirale (514) ;

dans un cas où la nouvelle séquence linéaire (520) coupe le contour interne (502) de la région, terminer le segment de trajectoire d'outil en spirale (514) au point d'intersection ;

une fois le deuxième point en spirale (518) calculé, mettre à jour le nombre restant de boucles à inclure dans le reste du segment de trajectoire d'outil (514) ; calculer récursivement les segments suivants du reste du segment de trajectoire d'outil en spirale (514) en prenant comme premier point le deuxième point en spirale.


 
16. Procédé d'usinage d'une pièce de fabrication utilisant une machine-outil contrôlée par ordinateur, le procédé comprenant :

sélectionner une région de ladite pièce à retirer par un outil de coupe rotatif ;

générer des commandes selon l'une quelconque des revendications 1 à 8 ; et

diriger, en utilisant les commandes générées, ledit outil de coupe rotatif le long d'une trajectoire d'outil en spirale asymétrique comprenant une pluralité de boucles dans ladite région de ladite pièce de fabrication, lequel chemin d'outil en spirale maximise une partie de ladite région de ladite pièce qui est retirée par ledit outil de coupe rotatif se déplaçant le long de ladite trajectoire d'outil en spirale asymétrique ;

dans lequel un angle d'engagement entre ledit outil de coupe rotatif et ladite pièce de fabrication varie progressivement entre un angle d'engagement maximum présélectionné et un angle d'engagement minimum présélectionné ;

dans lequel l'angle d'engagement varie pour ainsi faire varier la distance entre les boucles séquentielles plusieurs fois au cours de la trajectoire d'outil pour permettre à la trajectoire d'outil de se transformer entre deux formes géométriques différentes.


 




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REFERENCES CITED IN THE DESCRIPTION



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Patent documents cited in the description