Milling result visualization for assisting process planning of mold parts with complex pocket features

In the machining process planning of plastic molds, an estimation of the machining result that is realizable with a specific cutter is frequently needed. In this paper, we propose a novel method for computing the result shape using geometric models of the part, the workpiece before machining, and the cutter. This method is especially useful for mold parts with complex pocket features. The machining of a pocket uses a milling method with a cutter gradually approaching the pocket by following a downward slope. In this method, a gap distance is required between the cutter and the wall surfaces of the pocket. We have developed an inverted-offset-based method for evaluating this geometric constraint in the determination of the maximum milling depth of the pocket. Because this method does not consider any shape descriptions from the form feature database, it is applicable to any form features with certain depressions, like slot features.