IV.2 Intelligent Machining Systems - Challenges and Opportutinties

Accurate models and simulation systems of metal cutting processes are used to evaluate operational parameters (that is, feeds, speeds, depth of cut) with respect to critical process constraints, such as cutting loads, cutting stability, and produced part features. In this regard, process modeling is a major component of intelligent machining systems for optimization algorithms and for the generation of base line data for actual process evaluation. There are several aspects of metal cutting that make process simulation complex. The first involves the accurate calculation of the geometry of interaction between the tool and work piece—an issue compounded by the use of tooling and work pieces with complicated profiles. Moreover, for milling of dies and molds in particular, tool paths involve continuously varying immersion geometries with rough, semi finish, and finish passes. This introduces the need to manage very large amounts of data. Added to all of this is the requirement for inclusion of the effects of machine tool dynamics due to their critical effect on chip geometry.