Abstract: Pockets with complex geometry are usually machined on CNC machining tools, and the optimization of tool sequence significantly affects the rough machining time. In the process of tool sequence optimization, screening cutters is a basic work. However, most cutter screening methods are based on constraints extracted from pocket geometry, machining tools, and machining process, and rarely take constraints between cutters into consideration; thus, redundant cutters appear in feasible cutter set. A mathematic model is established for estimating validity of tool sequence by comparing benefits increment generated from cutters combination with benefits decrement generated from the tool-change process, in addition, a redundant cutter judging rule based on the model is constructed and demonstrated from the point of cutters combination forms. By connecting the existing cutters screening methods and the new rule for judging redundant cutters, a new cutters screening method for high performance tool sequence optimization is obtained. The technologies of the new method including the method for estimating cutter’s machining ability and the method for calculating validity of tool sequence are studied. A case study is introduced, which proves the practical value of the presented method.

Key words: Cutter screening, Pocket, Rough machining, Tool sequence, Co-Cu-Pb immiscible alloy, microstructure, rapid solidification, resistance property, metallic materials