Smooth Envelope Construction for Multi-Strip Flank Milling

Michal Bizzarri
Západočeská univerzita v Plzni, Plzeň

Geometric modeling provides a natural framework for 5-axis CNC tool-motion planning, which can be formulated as the approximation of a free-form surface by envelopes of moving rotational surfaces. A key geometric challenge is to construct neighboring envelope strips that approximate the target surface with high accuracy while forming smooth transitions without gaps or overlaps.

We present a multi-strip tool-motion planning method for conical and custom-shaped tools that promotes $G^1$ continuity between adjacent envelope strips.

Experiments on synthetic and industrial geometries demonstrate improved approximation accuracy and smoothness compared to existing approaches, highlighting the role of envelope geometry and tool-shape optimization in advanced CNC machining.