Freeform surface features are often machined with multiple operations. The geometry, tools, and cutting parameters of these operations have to be determined during process planning. In this paper, strategies and algorithms to decompose a freeform surface feature into multiple operations, which include roughing (facing and end milling), finishing, tapering, and corner rounding, are presented. For each operation, tool and parameter selections are based on minimizing machining time with the constraints of the specified roughness, tolerance, and machine tool safety. Geometry decompositions are based on the selected tools and the surface slope for the purpose of improving the cutting efficiency. Methods to control the quality requirements (roughness and tolerance) and to estimate the total machining time are also developed. In addition, the manufacturability of freeform surface features is discussed.

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