This paper concerns with free form surface reorganization and assessment of free form model complexity, grouping particular surface geometrical properties within patch boundaries, using self organized Kohonen neural network (SOKN). Neural network proved itself as an adequate tool for considering all topological non-linearities appearing in free form surfaces. Coordinate values of point cloud distributed at a particular surface were used as a surface property’s descriptor, which was led into SOKN where representative neurons for curvature, slope and spatial surface properties were established. On a basis of this approach, surface patch boundaries were reorganized in such a manner that finish machining strategies gave best possible surface roughness results. The patch boundaries were constructed regarding to the Gaussian and mean curvature, in order to achieve smooth transition between patches, and in this way preserve or even improve desired curve and surface continuities, (C2 and G2). It is shown that by reorganization of boundaries considering curvature, slope and spatial point distribution, the surface quality of machined free form surface is improved. Approach was experimentally verified on 22 free form surface models which were reorganized by SOKN and machined with finish milling tool-path strategies. Results showed rather good improvement of mean surface roughness profile Ra for reorganized surfaces, when comparing to unorganized free form surfaces.
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