Process planning for 2 1/2D pocket machining: a review

Pocket machining is an extensively used end milling operation with wide applications in aircraft and die/mold industries. Though simple in geometry, 2 1/2 D pocket machining has complicated planning issues, evident from the high volume of existing research work. In this paper, the literature addressing 2 1/2 D pocket machining has been reviewed to study the planning tasks and compare the different approaches in their operational planning. The different planning tasks, identified as Tool Selection, Tool Path Generation, and Machining Parameter Selection, involve different sets of process parameters and their individual research issues and considerations have been studied. It is observed that the optimization of each task is mostly treated in isolated fashion although they are linked to each other, through the cut geometry and cutting kinematics. The few attempts have been made to combine them, but in a sequential manner. Moreover, the conversation of the geometry of a 2 1/2 D pocket to the corresponding process related tasks is not unique that introduces discontinuities between the part design and machining process planning phases. Summary of the review of the process planning of 2 1/2 pocket identifies a need for novel framework for integrated process planning, based on the decompisition of the pocket geometry into elemental features with the corresponding planning tasks and simultaneous optimization of all the tasks in a structured manner.Peer reviewed: YesNRC publication: Ye