The goal of computer numerical control (CNC) machining for sculptured part finishing is to ensure the required-surface quality while maintaining maximum machining efficiency. This work addresses these challenging and conflicting tasks that demand more research.

In CNC machining, machining errors are usually caused by some of the sources such as cutting tool deflection, cutting tool wear, machine tool vibration, improper coolant, improper lubrication, and negative thermal effect.

In this thesis research work, a generic, geometric approach to predicting accurate machining errors caused by the tool-surface mismatch is proposed for 3-axis sculptured surface milling. To implement this new approach, a cutter contact (CC) point optimization system is also proposed for optimizing CC points along tool paths to ensure adequate surface quality without surface gouging. A semi-cylindrical part and a Non-Uniform Rational B-Spline (NURBS) surface part are used to illustrate this approach and to demonstrate its superiority

This thesis research work provides a profound understanding of the machining errors caused by the tool-surface mismatch. It not only contributes to tool path planning for 3-axis CNC millin of sculptured surface parts, but also has potential to benefit the aeronautic, automotive and die/mold manufacturing industries.