Browse > Article
http://dx.doi.org/10.1016/j.jcde.2015.12.001

Cutter-workpiece engagement determination for general milling using triangle mesh modeling  

Gong, Xun (Department of Mechanical Engineering, The University of British Columbia)
Feng, Hsi-Yung (Department of Mechanical Engineering, The University of British Columbia)
Publication Information
Journal of Computational Design and Engineering / v.3, no.2, 2016 , pp. 151-160 More about this Journal
Abstract
Cutter-workpiece engagement (CWE) is the instantaneous contact geometry between the cutter and the in-process workpiece during machining. It plays an important role in machining process simulation and directly affects the calculation of the predicted cutting forces and torques. The difficulty and challenge of CWE determination come from the complexity due to the changing geometry of in-process workpiece and the curved tool path of cutter movement, especially for multi-axis milling. This paper presents a new method to determine the CWE for general milling processes. To fulfill the requirement of generality, which means for any cutter type, any in-process workpiece shape, and any tool path even with self-intersections, all the associated geometries are to be modeled as triangle meshes. The involved triangle-to-triangle intersection calculations are carried out by an effective method in order to realize the multiple subtraction Boolean operations between the tool and the workpiece mesh models and to determine the CWE. The presented method has been validated by a series of case studies of increasing machining complexity to demonstrate its applicability to general milling processes.
Keywords
Cutter-workpiece engagement; Machining simulation; General milling; Cutting force; Triangle mesh;
Citations & Related Records
연도 인용수 순위
  • Reference
1 Gong H, Wang N. Analytical calculation of the envelope surface for generic milling tools directly from CL-data based on the moving frame method. Computer-Aided Design 2009;41:848-55.   DOI
2 Lee SW, Nestler A. Complete swept volume generation, Part I: swept volume of a piecewise C1-continuous cutter at five-axis milling via Gauss map. Computer-Aided Design 2011;43:427-41.   DOI
3 Lee SW, Nestler A. Complete swept volume generation, Part II: NC simulation of self-penetration via comprehensive analysis of envelope profiles. Computer-Aided Design 2011;43:442-56.   DOI
4 Blackmore D, Leu MC, Wang LP. The sweep-envelope differential equation algorithm and its application to NC machining verification. Computer-Aided Design 1997;29:629-37.   DOI
5 Altintas Y, Kersting P, Biermann D, Budak E, Denkena B, Lazoglu I. Virtual process systems for part machining operations. CIRP Annals -Manufacturing Technology 2014;63:585-605.   DOI
6 Chung YC, Park JW, Shin H, Choi BK. Modeling the surface swept by a generalized cutter for NC verification. Computer-Aided Design 1998;30: 587-94.   DOI
7 Aras E, Feng HY. Vector model-based workpiece update in multi-axis milling by moving surface of revolution. The International Journal of Advanced Manufacturing Technology 2011;52:913-27.   DOI
8 Jerard RB, Hussaini SZ, Drysdale RL, Schaudt B. Approximate methods for simulation and verification of numerically controlled machining programs. The Visual Computer 1989;5:329-48.   DOI
9 Park JW, Shin YH, Chung YC. Hybrid cutting simulation via discrete vector model. Computer-Aided Design 2005;37:419-30.   DOI
10 Lee SW, Nestler A. Virtual workpiece: workpiece representation for material removal process. The International Journal of Advanced Manufacturing Technology 2012;58:443-63.   DOI
11 Gong X, Feng HY. Triangle mesh based in-process workpiece update for general milling processes. In: Proceedings of the ASME 2013 Interna-tional Design Engineering Technical Conferences & Computers and Information in Engineering Conference; Aug 4-7, 2013; Portland, Oregon; Paper DETC2013-12408.
12 Bernardini F, Mittleman J, Rushmeier H, Silva C, Taubin G. The ball-pivoting algorithm for surface reconstruction. IEEE Transactions on Visualization and Computer Graphics 1999;5:349-59.   DOI
13 Moller T. A fast triangle-triangle intersection test. Journal of Graphics Tools 1997;2:25-30.
14 Fussell BK, Jerard RB, Hemmett JG. Modeling of cutting geometry and forces for 5-axis sculptured surface machining. Computer-Aided Design 2003;35:333-46.   DOI
15 Imani BM, Sadeghi MH, Elbestawi MA. An improved process simulation system for ball-end milling of sculptured surfaces. The International Journal of Machine Tools and Manufacture 1998;38:1089-107.   DOI
16 Bailey T, Elbestawi MA, El-Wardany TI, Fitzpatrick P. Generic simula-tion approach for multi-axis machining, Part 1: modeling methodology. ASME Journal of Manufacturing Science and Engineering 2002;124: 624-33.   DOI
17 Sadeghi MH, Haghighat H, Elbestawi MA. A solid modeler based ball-end milling process simulation. The International Journal of Advanced Manufacturing Technology 2003;22:775-85.   DOI
18 Yao Z, Joneja A. Computing cutter engagement values in milling tessellated free-form surfaces. ASME Journal of Computing and Informa-tion Science in Engineering 2010;10:041005.   DOI
19 Larue A, Altintas Y. Simulation of flank milling processes. The Interna-tional Journal of Machine Tools and Manufacture 2005;45:549-59.   DOI
20 Aras E, Yip-Hoi D. Geometric modeling of cutter/workpiece engagements in three-axis milling using polyhedral representations. ASME Journal of Computing and Information Science in Engineering 2008;8:031007.   DOI
21 Ferry W, Yip-Hoi D. Cutter-workpiece engagement calculations by parallel slicing for five-axis flank milling of jet engine impellers. ASME Journal of Manufacturing Science and Engineering 2008;130:051011.   DOI
22 Du S, Surmann T, Webber O, Weinert K. Formulating swept profiles for five-axis tool motions. The International Journal of Machine Tools and Manufacture 2005;45:849-61.   DOI
23 Wang WP, Wang KK. Geometric modeling for swept volume of moving solids. Computer Graphics and Applications 1986;6:8-17.
24 Chiou C-J, Lee Y-S. A shape-generating approach for multi-axis machining G-buffer models. Computer-Aided Design 1999;31:761-76.   DOI
25 Chiou C-J, Lee Y-S. Swept surface determination for five-axis numerical control machining. The International Journal of Machine Tools and Manufacture 2002;42:1497-507.   DOI
26 Yip-Hoi D, Huang X. Cutter/workpiece engagement feature extraction from solid models for end milling. ASME Journal of Manufacturing Science and Engineering 2006;128:249-60.   DOI
27 El-Mounayri H, Elbestawi MA, Spence AD, Bedi S. General geometric modelling approach for machining process simulation. The International Journal of Advanced Manufacturing Technology 1997;13:237-47.   DOI
28 Sheltami K, Bedi S, Ismail F. Swept volumes of toroidal cutters using generating curves. The International Journal of Machine Tools and Manufacture 1998;38:855-70.   DOI
29 Roth D, Bedi S, Ismail F, Mann S. Surface swept by a toroidal cutter during 5-axis machining. Computer-Aided Design 2001;33:57-63.   DOI
30 Aras E. Generating cutter swept envelopes in five-axis milling by two-parameter families of spheres. Computer-Aided Design 2009;41:95-105.   DOI