General geometric modelling approach for machining process simulation

Machining process simulation systems can be used to verify NC (numerically controlled) programs as well as to optimise the machining phase of the production. These systems contribute towards improving the reliability and efficiency of the process as well as the quality of the final product. Such systems are particularly needed by industries dealing with complex cutting operations, where the generation of NC code represents a very complex and error-prone task. A major impediment to implementing these systems is the lack of a general and accurate geometric method for extracting the required geometric information. In this paper, a novel approach to performing this task is presented. It uses a general and accurate representation of the part shape, removed material, and cutting edges, and can be used for any machining process. Solid models are used to represent the part and removed material volume. Bezier curves (in 3D space) are used to represent cutting edges. It is shown that by intersecting the removed material volume with the Bezier curves, in-cut segments of the tool cutting edges can be extracted. Using these segments, instantaneous cutting forces as well as any other process parameters can be evaluated. It is also shown that by using B-rep (Boundary representation) polyhedral models for representing solids, and cubic Bezier curves for representing cutting edges, efficient, generic procedures for geometric simulation can be implemented. The procedure is demonstrated and verified experimentally for the case of ball end-milling. A very good agreement was found between simulated cutting forces and their experimental counterparts. This proves the validity of the new approach.