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tracing the edge of a cutting tool (toolpath)

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I imagine there must be a proper way to do this, but I wasn't able to look up a good (or any) algorithm.

 

Imagine you're cutting something on a mill.  You specify a trajectory for the cutting tool.  You're interested in the edges of the tool as it goes along the trajectory.  So imagine this tool path with this radius:

 

01.png

 

I have come up with a way to trace out the edge by taking derivatives of the trajectory, and then getting points on the circle perpendicular to the slope.  I get something like this:

02.png

 

What if I just want the "envelope" of the edges?  My edge traces do a loop/wrap-around when there are small turning radii.  See what happens to the green edge when it hits the "armpit."  The envelope would not include the inner loop.

 

I had another idea where I can use an image processing approach.  So create a black and white image representing the trail of the circles, and then do an edge-find to get the envelope.  The pixels can then be translated by to coordinates.  I hesitate on this approach as it is not as mathematically "pure."

 

Thoughts?


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