• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.26 no.9
• /
• pp.1814-1821
• /
• 2002

NC cutting simulation is an important factor in the development of products. The geometric modelling of cutter swept surface should be done in NC cutting simulation. A part of cutter swept surface is a ruled surface blended with silhouette curve and cutter path. Finding an intersection point between cutter swept surface and a line is one of major problems in Z-map based cutting simulation. In this paper, cutter swept surface is defined parametrically and it's intersection point with Z-map is found in an exact form. Triangular grid Z-map based 3-axis NC cutting simulation is performed.

• Korean Journal of Computational Design and Engineering
• /
• v.1 no.1
• /
• pp.45-55
• /
• 1996

This paper presents a new approach to non-parametric modeling of cutter swept surface (CSS) for cutting simulation. Instead of explicitly modeling cutter swept volumes, silhouette curves of the cutter surface are utilized in computing the z-value of the CSS at a grid point on the x,y-plane. The non-parametric evaluation of the CSS constitutes the integral part of 3-axis cutting simulation. The proposed method is more efficient than the existing ones in the case of conventional cutters (i.e., ball-end mills and flat-end mills), and more importantly, it enables the non-parametric modeling of the CSS for the round-end mills which was not possible with the existing methods.

• Proceedings of the KSME Conference
• /
• 2001.06c
• /
• pp.235-239
• /
• 2001

Finding intersection point between a surface and a line is one of major problem in CAD/CAM. The intersection point could be found in an exact form or with numerical method. In this paper, the exact solution of the intersection point between a ruled surface which is generated by the movement of an endmill and the z-direction vector is presented. The cutter swept surface which is a ruled surface and the Z-direction vector are represented with parametric equations. With the nature of parametric equations, the geometric properties at the intersection point are easily acquired.

• Korean Journal of Computational Design and Engineering
• /
• v.9 no.1
• /
• pp.35-43
• /
• 2004

It is well known that the five-axis machining has advantages of tool accessibility and machined surface quality when compared with conventional three-axis machining. Traditional researches on the five-axis tool-path generation have addressed interferences such as cutter gouging, collision, machine kinematics and optimization of a CL(cutter location) or a cutter position. In the paper it is presented that optimal CL data for a face-milling cutter moving on a tool-path are obtained by incorporating TSS(tool swept surface) model. The TSS model from current CL position to the next CL position is constructed based on machine kinematics as well as cutter geometry, with which the deviation from the design surface can be computed. Then the next CC(cutter-contact) point should be adjusted such that the deviation conforms to given machining tolerance value. The proposed algorithm was implemented and applied to a marine propeller machining, which proved effective from a quantitative point of view. In addition, the algorithm using the TSS can also be applied to avoid cutter convex interferences in general three-axis NC machining.

• International Journal of CAD/CAM
• /
• v.3 no.1_2
• /
• pp.1-12
• /
• 2003

When milling concave corners, cutter load increases momentarily and fluctuates severely due to concentration and uneven distribution of material stock. This abrupt change of cutter load produces undesirable machining results such as wavy machined surface and cutter breakage. An important factor for studying cutter load in 2.5D pocket milling is the instantaneous Radial Depth of Cut (RDC). However, previous work on RDC under different corner-cutting conditions is lacking. In this different corner shapes. In our work, we express RDC mathematically in terms of the instantaneous cutter engage angle which is defined as Cutter Swept Angle (CSA). An analytical approach for modeling CSA is explained. Finally, examples are shown to demonstrate that the proposed CSA modeling method can give an accurate prediction of cutter load pattern at cornering cut.

• Journal of the Korean Society for Precision Engineering
• /
• v.13 no.6
• /
• pp.161-167
• /
• 1996

In five-axis milling, optimal CL-data (cutter location data) should be generated to have advantages over three-axis milling in terms of accuracy and efficiency. This paper presents an algorithm for generating collision-free CL-data for five-axis milling using potential energy method. By virtually charging the cutter and part surfaces with static electricity, global collision as wells as local interference is eliminated. Additionally, machining efficiency is improved by minimizing the curvature difference between the part surface and tool swept surface at a CC-point (cutter contact point) simultaneously.

• Proceedings of the KSME Conference
• /
• 2008.11a
• /
• pp.1053-1056
• /
• 2008

An application of CSG (Constructive Solid Geometry) modeling technique in Machining Simulation is introduced in this paper. The current CSG model is based on z-buffer CSG Rendering Algorithm. In order to build a CSG model, frame buffers of VGA (Video Graphic Accelerator) should be used in term of color buffer, depth buffer, and stencil buffer. In addition to using CSG model in machine simulation Stock and Cutter Swept Surface (CSS) should be solid. Method to create a solid Cuboid stock and Ball-end mill CSS are included in the present paper. Boolean operations are used to produce the after-cut part, especially the Difference operation between Stock and CSS as the cutter remove materials form stock. Finally, a small program called MaSim which simulates one simple cut using this method was created.