Disclosed is a method and apparatus for machining a workpiece (2). The method comprises: specifying a path along which a cutting tool (6) is to be moved during machining of the workpiece (2), the path comprising a plurality of segments (26); defining, for each segment (26), an entry point and an entry path (32) from a point remote from the workpiece (2) to that entry point; moving a first cutting tool (6) along the tool path from a first point to a second point and machining the workpiece (2); after the first cutting tool (6) has been moved to the second point, moving the first cutting tool (6) to a point remote from the workpiece (2); moving a second cutting tool (18) along the entry path (32) of the segment (26) that contains the second point, and then from the entry point to the second point.

Disclosed is a method and apparatus for machining a workpiece (2). The method comprises specifying a path along which a cutting tool (6) is moved during machining the workpiece (2), the path comprising segments (26); defining, for each segment (26), an exit point on that segment (26); defining, for each segment (26), an exit path (38) from the exit point of that segment (26) to a point remote from the workpiece (2); performing a machining process including moving the cutting tool (6) along the tool path and machining the workpiece (2); and, during the machining process, when one or more criteria are satisfied: interrupting the machining process and, without machining the workpiece (2), moving the cutting tool (6) to the exit point of the current segment (26) and then along the exit path (38) of the current segment (26).

Optimized positioning paths for multi-axis CNC machining can be generated based on the machine tool kinematics, machine axes travel limits, machine axis velocity and acceleration limits, and machine positioning methodologies. Machine axes travel limits and machine positioning methodologies are incorporated in order to ensure that the developed positioning paths do not violate machine axes travel limitations. Multi-axis positioning paths are developed to avoid collisions with dynamically changing in-process stock and other surroundings, including fixtures and both moving and non-moving components of the machine. Positioning tool path customizations give the user the flexibility to apply safety based constraints to the automatically generated tool paths. The disclosed automatic positioning path planning and optimization methods are used to develop a process for part manufacturing using CNC machining in order to reduce the manufacturing cycle time.

A system and method for measuring a distance to a target work surface to precisely position a tool assembly coupled to an actuator. The method includes measuring a distance to a work surface using a distance sensor, moving the tool assembly into an approach position, the approach position being adjacent to a location on the work surface. The tool assembly is then moved from the approach position to the location on the work surface pursuant to a soft landing procedure. The soft landing procedure may include determining that the tool assembly has moved into soft contact with the target work surface. Methods also include topologically mapping a work surface, comparing map data to predefined data, and adjusting a positioning routine. Additionally, methods include optimizing actuator movements to timely measure distances from a distance sensor to a location on a work surface with minimal actuator movement.