| Over the past twenty-five years, considerable progress has been made in the development of theories, methodologies, and systems for computer-integrated design, process planning, and manufacturing. However, even state-of-the-art CAD/CAM systems require the user to make many basic decisions pertaining to process planning and cutter-path generation (such as selection of cutting tool sizes) that can significantly affect the quality of the resulting solution (in terms of machining time and production cost). Due to the combinatorial and complex nature of the decisions to be made, the user often makes subjective, conservative, and consequently non-optimal decisions.; The overall goal of the research is to develop methodologies and algorithms for optimal tool set selection and tool path planning (including machining parameters) that will minimize the processing time for rough machining and finish machining of sculptured surface cavities on a 3-axis CNC milling machine.; A new geometric construct called the Voronoi Mountain has been developed and used in conjunction with the One-Fold and Two-Fold Dynamic Programming approaches respectively for determination of the optimal set of cutting-tools and the corresponding tool path plan for rough machining of generalized 2 1/2 D and 3D cavities.; For finish machining, the Up-down approach for identifying the largest gouge-free cutting-tool size for finishing a 3D cavity has been developed. To determine the best isoparametric machining strategy and the best machining orientation for a given patch, the Relative Difference approach and the Transition Point approach have respectively been developed. Finally, transformation approaches for determination of an optimal tool path plan for finish machining a compound surface have been developed.; The results of the research can significantly enhance the capabilities of CAD/CAM systems and thereby increase the competitiveness of manufacturing companies. |
