Flexible Tool-path Generation for Variable Geometry

Assembled components often exhibit slight geometric variations from CAD nominal positions. In such cases, there is a desire to retain the expert knowledge of experienced manufacturing engineers using advanced CAM tool path planning software, while enabling adjustment of the tool paths to accommodate the actual measured assembly geometry. This paper proposes a new paradigm for accomplishing synergy between off line a priori expert CAM planning, specific assembly geometry laser digitizer based measurement, point cloud registration to nominal CAD orientation, and actual geometry guided tool path adjustment. A lightweight implementation that requires modest computing resources, can be located on the factory floor, and does not require a dedicated CAM software seat, is used. Early experimental demonstration uses round parts, weld fillets, and 3-axis machining, but the method is ultimately intended for use with applications such as injection moulds, sheet metal stamping dies, and 5-axis gas turbine component manufacturing.