Abstract: The strategy for die/mold cavity CNC rough machining is transforming from traditional single-tool approach to a combination of several cutting tools due to the application of high-speed CNC center. Tool combination optimization for roughing can increase the total machining efficiency significantly. The tool selection by using existing CAM software is mainly based on experience, so it is error-prone and hard to reach optimum results. A systematic methodology for automatic tool selection in die/mold cavities roughing based on CAD model intersecting by a series of hunting planes is proposed. A mathematical model for tool combination optimization is established, and various algorithms, including loop generation, inner and outer loop identification and hunting layer merging, are presented. The methodology is implemented in UG/open context, and two examples are given to show the validity and feasibility of the proposed methodology.

Key words: CNC, Die/mold cavity, Optimization, Sculptured surface, Tool selection