Predicting the variations in process dynamics during sculptured surface machining

This paper presents a generic methodology to simulate the dynamic process as a continuous solution for complex sculptured surface machining. The simulation includes the instantaneous deflection of the tool and its history over the entire tool path. The simulation results are compared with published static and dynamic modeling technologies based on control points. The comparison is made for linear cuts with constant and variable immersion ratios. The results show that the proposed methodology outperforms other control point methods and offers a good representation of the static and dynamic cutting force and tool deflection in three-axis machining of sculptured surfaces.