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Cusp modeling for 5-axis surface machining

Gouge checking and gouge measuring are essential parts of 5-axis tool-positioning strategies. To evaluate the quality of a tool path (i.e. the remaining material, commonly referred to as cusps), machining tests must usually be performed. If the tests prove to be unsatisfactory, new tool paths must be generated and run. In this paper, a new approach for modeling cusps is presented which makes use of recent advances in vector algebraic computation of swept volumes. The method uses the computer's graphics card to compute the cusp geometry from the swept volumes. The algorithm was verified with a machining test by measuring the cusp height between two adjacent passes with a Coordinate Measuring Machine and comparing it to the modeled cusp height.