Automatic selection of an optimal toolset for 2.5 D pocket milling

In order to enhance productivity and automate the rough milling process of pockets, it is crucial to select the optimal set of tools that offer reduced cutting time. In this article, a new method for the automatic selection of a toolset has been developed to effectively remove material during the roughing stage of a pocket with any contour, whether formed by line–line or line–arc, convex or concave. The proposed software selects a maximum of three tools based on the pocket's boundary. These algorithms test available tool combinations on the machine tool and provide the suitable toolset that minimizes cutting time further. This is done through a visual test, and if the residue in the corners takes the form of a polygon, an algorithm adds a third tool. In this case, the software will choose the best combination, either two or three tools, that minimizes machining time even more. The good news is that the machining simulation and the result file are obtained in a reduced time. It also provides the toolpath coordinates that can be transferred directly to the machine. To demonstrate the effectiveness of our approach, we also conducted a detailed comparison with conventional methods found in the literature. The results obtained show that our new approach minimizes both toolpath length and cutting time with the optimal toolset compared to other methods.