A robust method is proposed to generate tool paths for NURBS-based machining of arbitrarily shaped freeform pockets with islands. Although the input and output are all of higher-degree NURBS curves, only one simple category of geometric entities, i.e., line segments, is required for initial offsetting and for detecting and removing self-intersecting loops. Furthermore, using those linear non-self-intersecting offsets as the legs of NURBS control polygons, NURBS-format tool paths can be smoothly reconstructed with G(1)-continuity, no overcutting, no cusps, and global error control. Since all operations involved in computing tool path curves are linear geometric calculations, the method is robust and simple. Examples with integrated rough and finish cutting tool paths of pockets demonstrate the usefulness and effectiveness of this method.
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