Maximization of slice height with uniformity in surface roughness in the direct slicing of freeform surfaces

Abstract

In most of the direct slicing strategies, the deviation between the computer aided design (CAD) model and the built-up part is estimated as the cusp height in normal vertical sections (NVSs) at points all around the slice contour. In the present investigation, the error is also estimated in inclined normal sections (INSs) in an attempt to maximize the slice height and simultaneously obtain a uniform surface roughness of the part. It is found that the number of slices is drastically reduced by the application of the proposed strategy when compared with first-order approximation with error calculation in NVSs. It is also interesting to note that slice height maximization is not necessarily accompanied with any significant, simultaneous reduction in machining time.