Journal ArticleDOI
A comparison of solid model and three-orthogonal dexelfield methods for cutter-workpiece engagement calculations in three- and five-axis virtual milling
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TLDR
In this paper, two different methods of obtaining CWE maps for three and five-axis flat and ball-end milling are developed, one is a discrete model which uses three-orthogonal dexelfield, and the second method is a solid modeler-based model using Parasolid boundary representation kernel.Abstract:
Virtual simulation of three- and five-axis milling processes has started to become more important in recent years in various industries such as aerospace, die-mold, and biomedical industries in order to improve productivity. In order to obtain desired surface quality and productivity, process parameters such as feedrate, spindle speed, and axial and radial depths of cut have to be selected appropriately by using an accurate process model of milling. Accurate process modeling requires instantaneous calculation of cutter-workpiece engagement (CWE) geometry. Cutter-workpiece engagement basically maps the cutting flute entry/exit locations as a function of height, and it is one of the most important requirements for prediction of cutting forces. The CWE calculation is a challenging and hard problem when the geometry of the workpiece is changing arbitrarily in the case of five-axis milling. In this study, two different methods of obtaining CWE maps for three- and five-axis flat and ball-end milling are developed. The first method is a discrete model which uses three-orthogonal dexelfield, and the second method is a solid modeler-based model using Parasolid boundary representation kernel. Both CWE calculation methods are compared in terms of speed, accuracy, and performance for three- and five-axis milling of ball-end and flat-end mill tools. It is shown that the solid modeling-based method is faster and more accurate. The proposed methods are experimentally and computationally verified in simulating milling of complex three-axis and five-axis examples as well as predicting cutting forces.read more
Citations
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Journal ArticleDOI
Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics
Danil Yurievich Pimenov,Amauri Hassui,Szymon Wojciechowski,Mozammel Mia,Aristides Magri,Daniel Suyama,Andres Bustillo,Grzegorz Królczyk,Munish Kumar Gupta +8 more
TL;DR: In this article, the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution).
Journal ArticleDOI
Machining deformation prediction of thin-walled workpieces in five-axis flank milling
Liping Wang,Hao Si +1 more
TL;DR: In this article, an efficient cutter-workpiece engagement (CWE) extraction method was proposed for the computation of cutting forces and identification of machining geometry changes during the five-axis flank milling process.
Journal ArticleDOI
Arc-surface intersection method to calculate cutter-workpiece engagements for generic cutter in five-axis milling
TL;DR: A new arc-surface intersection method (ASIM) is proposed to obtain CWEs for generic cutter in five-axis milling and the results indicate that the ASIM is computationally efficient, accurate and robust.
Journal ArticleDOI
Stability prediction of five-axis ball-end finishing milling by considering multiple interaction effects between the tool and workpiece
TL;DR: In this paper, a new five-axis ball-end machining dynamical model which considers the multiple interactions between the tool and workpiece is established for the first time, and the effects of regenerative effect, structural mode coupling and process damping on the dynamic characteristics of 5-axis milling are investigated.
Journal ArticleDOI
Machining strategy development and parameter selection in 5-axis milling based on process simulations
TL;DR: In this paper, an approach is proposed for the use of process models and simulation tools in this direction, where cutting force and stability simulations are used in identification of feasible regions of cutting parameters and comparison of machining strategies for productivity.
References
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Journal ArticleDOI
Geometric Modeling for Swept Volume of Moving Solids
W.P. Wang,K.K. Wang +1 more
TL;DR: A novel method for modeling swept voume by computing a family of critical curves from a moving solid is presented, developed for real-time verification of NC tool paths using computer graphics.
Journal ArticleDOI
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TL;DR: In this paper, the authors present an overview of recent developments in simulating machining and grinding processes along the NC tool path in virtual environments, and present the present and future challenges to achieving a more accurate and efficient virtual machining process simulation and optimization system.
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Real-time shaded NC milling display
TL;DR: The real-time shaded display of a solid model being milled by a cutting tool following an NC path is attained by the image-space Boolean subtraction of solid objects.
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Cutting force prediction of sculptured surface ball-end milling using Z-map
TL;DR: In this article, the cutting forces acting on the engaged cutting edge elements are calculated using an empirical method using the Z-map of the surface geometry and current cutter location to determine cutting edge element engagement.
Journal ArticleDOI
Modeling of cutting geometry and forces for 5-axis sculptured surface machining
TL;DR: 5-Axis sculptured surface machining is simulated using discrete geometric models of the tool and workpiece to determine the tool contact area, and a discrete mechanistic model to estimate the cutting forces.