Machining large complex shapes using a 7 DoF tool

Abstract

A new approach to the refixturing-free fabrication of large, arbitrarily complex shapes has been developed. Based on an enhanced accessibility analysis of the target shape, a reduced set of candidate machining orientations is determined. Then, machining takes place at very close distance between the tooling machinery and the part, thus achieving effective material removal in complex regions. Minkowski operations on the involved (dynamic) volumes are performed to update their multi-map representations. Performance tests, both virtual and physical, show that it is possible to automatically find the strategy for material removal and for tool path planning. The method has been implemented on the 7 DoF Sculpturing Robot at the Faculty of