International Journal For Multidisciplinary Research

E-ISSN: 2582-2160   •   Impact Factor: 9.24

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Integrated Geometric Cutter Selection and Machining-Time Optimization for Rough Machining of NURBS-Based Free-Form Surfaces: A Theoretical Framework

Author(s) Dr. Ali Serhat ERSOYOĞLU
Country Turkey
Abstract Free-form surface machining is a challenging computer-aided manufacturing problem because local surface geometry continuously affects cutter accessibility, tool engagement, toolpath generation, and machining efficiency. In rough machining, cutter selection is particularly important because a substantial amount of material is removed and the selected cutter influences both cutting and non-cutting operations. This paper develops a theoretical framework that extends the authors' previously published NURBS/IGES-based geometric cutter-selection methodology into a global discrete cutter-assignment and machining-time optimization model. The contribution is not claimed to be the first introduction of tool selection, airtime minimization, or machining-time optimization; these topics have been addressed previously. Instead, the proposed framework explicitly connects layer- and island-based geometric cutter feasibility with discrete cutter-to-region assignment and a unified nominal process-time objective containing cutting, air-travel, and tool-change contributions. The formulation distinguishes local geometric feasibility from global process optimality and provides a small analytical counterexample showing that the largest feasible cutter for each individual region need not constitute the globally preferred cutter combination. The study is intentionally theoretical; the numerical illustration is used only to verify the mathematical behavior of the formulation and is not presented as experimental validation. The framework provides a transparent basis for future CAD/CAM implementation and for extensions involving force, energy, tool wear, and five-axis kinematics.
Keywords Free-form surface; cutter selection; toolpath optimization; NURBS; rough machining; machining time; CAD/CAM; process planning.
Field Engineering
Published In Volume 8, Issue 4, July-August 2026
Published On 2026-08-16
DOI https://doi.org/10.36948/ijfmr.2026.v08i04.85671
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CrossRef DOI prefix of IJFMR is 10.36948/ijfmr

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