This study develops a novel framework for generating multi-axis rough milling tool path by leveraging a full 3D Hodge decomposition of the volume-vector field (VFD). First, the stock material is tetrahedralized to form a computational mesh, on which a discrete five-term Hodge decomposition is performed. This process yields two orthogonal harmonic fields: a normal field that delineates the “near-net” rough-machining layers conforming precisely to the target geometry, and a tangential field that generates smooth, raster cutter-contact (CC) curves on each layer. Moreover, by taking the cross-product of these two fields, one can derive continuous, smooth circumferential CC curves. By enforcing mixed boundary conditions and incorporating a scallop-height-constrained scalar field, the method achieves graded layer thickness for material removal while precisely controlling residual heights. A tool-orientation planning module assigns collision-free, smoothly varying orientations along each CC curve, and CC-curve sequencing is optimized to minimize tool repositioning and idle motion. Comparative experiments on complex parts demonstrate that the VFD-based method not only guarantees complete, collision-free rough machining but also reduces total toolpath length and machining time while achieving effective residual-height control—outperforming both 3D area-clearance and blisk area-clearance strategies. Relative to an advanced geodesic-distance–based method, the VFD-based method shows markedly lower sensitivity to mesh resolution and therefore greater robustness. This work constitutes the first rigorous application of 3D Hodge theory to CNC rough machining and provides a flexible, efficient solution for five-axis volumetric machining.
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