Efficient, accurate geometric modeling for three-axis sculptured surfaces milling is quite challenging due to complexity of workpiece geometry change during machining. This paper presents an efficient, accurate approach to extracting the cutter/workpiece engagement (CWE) geometry and applying this geometry to an existing mechanistic force model in order to predict instantaneous cutting force, torque and power. In our research, a basic geometric modeling of chip removal in three-axis milling is investigated, and an effective model is proposed to represent the cutter swept profile. Computationally efficient, closed-form formulations are derived for general APT (Automatically Programmed Tools) cutter geometry. A Z-level B-Rep model is adopted to represent the in-process workpiece model, and an innovative geometric approach is used to extract the CWE geometry. Then, a mechanistic cutting force model is integrated to predict the cutting forces. As a result, a milling process simulation system is developed for three-axis virtual milling of sculptured surfaces. The developed system is experimentally verified by comparing the simulation results with actual forces measured from machining a test surface.
- Design Engineering Division and Computers in Engineering Division
Efficient, Accurate Geometric Modeling for Three-Axis Sculptured Surfaces Milling
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Fu, Q, & Chen, ZC. "Efficient, Accurate Geometric Modeling for Three-Axis Sculptured Surfaces Milling." Proceedings of the ASME 2010 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. Volume 6: 15th Design for Manufacturing and the Lifecycle Conference; 7th Symposium on International Design and Design Education. Montreal, Quebec, Canada. August 15–18, 2010. pp. 565-574. ASME. https://doi.org/10.1115/DETC2010-28910
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