Forming stylus tool design and toolpath generation module for 3 axis computer numerical control manufacturing processes

A toolpath generation method using a toolpath generation module of a part forming machine for generating a toolpath using a stylus tool, the toolpath generation method comprising:

• inputting a part shape of a part to be manufactured;
• inputting a tool shape of the stylus tool based on a convex forming surface of a head of the tool between a tip of the head and a base of the head defined by revolving an uninterrupted curved profile around an axis of the stylus tool, the curved profile having a convex curvature changing linearly with a curve length of the curved profile of the convex forming surface, the head of the tool having a circular cross-section about the axis, wherein the curved profile of the convex forming surface is part a clothoid;
• determining a tool offset surface for the part shape based on the tool shape;
• and
• generating the toolpath for forming the part based on the tool offset surface.

A toolpath generation method using a toolpath generation module of a part forming machine for generating a toolpath using a stylus tool, the toolpath generation method comprising:

• inputting a part shape of a part to be manufactured;
• inputting a tool shape of the stylus tool based on a convex forming surface of a head of the stylus tool between a tip of the head and a base of the head defined by a curved profile, the curved profile being differentiable and bounding a convex region, the convex forming surface being axisymmetric for forming of the part, the convex forming surface being defined by an uninterrupted surface of revolution generated by revolving a curved profile around the axis of the stylus tool, the curved profile having a convex curvature changing linearly with a curve length of the curved profile of the convex forming surface, the head of the tool having a circular cross-section about the axis, wherein the curved profile of the convex forming surface is part of a clothoid;
• inputting a tool size of the base of the head of the stylus tool;
• determining a tool offset surface for the part shape based on the tool shape and the tool size;
• and
• generating the toolpath for forming the part based on the tool offset surface and the part shape.

A part forming machine comprising:

• a collet;
• a tool positioner operably coupled to the collet to move the collet in a three dimensional working space;
• a controller operably coupled to the tool positioner for controlling a position of the collet in the working space, the controller including a toolpath generation module for generating a toolpath for forming of a part;
• and
• a stylus tool coupled to the collet for forming the part, the stylus tool including a tool body extending between a shank and a head, the shank being coupled to the collet, the head extending between a base at the shank and a tip, the head having a convex forming surface between the base and the tip, the convex forming surface being axisymmetric for forming of the part, the convex forming surface being defined by a curved profile having a convex curvature being differentiable and bounding a convex region, the convex forming surface being defined by rotating a curved profile around an axis of the shank, the convex forming surface being an uninterrupted surface of revolution generated by revolving the curved profile around the axis, the curved profile having a convex curvature changing linearly with a curve length of the curved profile of the convex forming surface, the head having a circular cross section about the axis, wherein the curved profile of the convex forming surface is part of a clothoid;
• wherein the toolpath generation module determines the toolpath for the stylus tool based on a tool shape of the stylus tool defined by the convex forming surface.

A part forming machine comprising:

• a collet;
• a tool positioner operably coupled to the collet to move the collet in a three dimensional working space;
• a controller operably coupled to the tool positioner for controlling a position of the collet in the working space, the controller including a toolpath generation module for generating a toolpath for forming of a part;
• and
• a stylus tool coupled to the collet being movable by the collet for forming the part, the stylus tool including a tool body extending between a shank and a head, the shank being coupled to the collet, the head extending between a base at the shank and a tip, the head having a convex forming surface between the base and the tip, the convex forming surface being axisymmetric for forming of the part, the convex forming surface being defined by an uninterrupted surface of revolution generated by revolving a curved profile around an axis of the shank, the curved profile having a convex curvature changing linearly with a curve length of the curved profile of the convex forming surface, wherein the curved profile of the convex forming surface is part of one of a clothoid, a filleted rectangle, a parabola, or an ellipse;
• wherein the toolpath generation module determines the toolpath for the stylus tool based on a tool shape of the stylus tool defined by the convex forming surface.