• Journal of the Korean Society for Precision Engineering
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• v.20 no.5
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• pp.47-56
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• 2003

Geometric cutting-simulation and verification play an important role in detecting NC machining errors in mold & die manufacturing and thereby reducing correcting time & cost on the shop floor. Current researches in the area may be categorized into view-based, solid-based, and discrete vector-based methods mainly depending on workpiece models. Each methodology has its own strengths and weaknesses in terms of computing speed, representation accuracy, and its ability of numerical inspection. The paper proposes a hybrid modeling scheme for workpiece representation with z-map model and discrete vector model, which performs 3-axis and 5-axis cutting-simulation via tool swept surface construction by connecting a sequence of silhouette curves.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.12
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• pp.86-92
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• 2002

This paper presents a new model of NC verification in NC milling using z-map. The model can describe the motion of machine tool like a real machine effectively. The model uses x, y, and z directional feed rate as well as cutting data for modeling Z-map of workpiece. The model verifies the over-cut, the under-cut and the surface topography using NC codes and cutting conditions. To investigate the performance of the model, simulation study was carried out. As the results, the model gave the geometry accuracy of workpiece, the surface topography, and the chip loads.

• Journal of the Korean Society of Industry Convergence
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• v.4 no.4
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• pp.365-369
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• 2001

This paper presented a new model of virtualized CNC milling machine. The model verifies the over cut, the under cut and the surface roughness using NC file generated from CAM and cutting condition. The model uses Z-map model to verify workpiece. In this paper, the model used the velocities of x, y and z direction and obtained a center point of a hall end mill for modeling Z-map of workpiece. To investigate the performance of the model, simulation study was carried out. As the results, the model gave geometry accuracy of workpiece, the surface roughness and the chip loads in finish cutting that can predict tool chipping. The virtualized CNC machine can he used a flat end mill, a ball end mill and a rounded end mill.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.873-876
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• 2003

Z-map model is the most widely used model for NC simulation and verification. But it has several limitations to get a high precision, to apply 5 axis machining simulation. In this paper, we tried to use quadtree for searching cutting region. Quadtree representation of two dimensional objects is performed with a tree that describes the recursive subdivision. By using these quadtree model. storage requirements were reduced. And also, recursive subdivision was processed in the boundries, so, useless computation could be reduced, too. To get more high Accuracy, we applied the supersampling method in the boundaries. The Supersampling method is the most common form of the antialiasing and usually used with polygon mesh rendering in computer graphics To verify quadtree model we compared simulated results with z-map model and enhanced z-map model

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.3
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• pp.83-91
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• 1999

In this paper, we suggest a virtual machining system that can simulate cutting forces of ball end milling at the stage of part design. Cutting forces, here, are estimated from the machanistic model that uses the concept of specific cutting farce coefficient. To this end, we need undeformed chip thickness which is used for calculating chip load. It is derived from the Z-map data of a CAD model. That is, chip load is the height difference between the cutting tool and the workpiece at an arbitrary position. The tool contact point is referred from the cutter location data. On the other hand, the workpiece height is acquired from the Z-map model of a CAD data. From the experimental verification, we can simulate machining process effectively to the slot and the side cutting of ball end mill.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.4
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• pp.68-75
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• 2005

This paper presents a new method for the optimization of feed rate in sculptured surface machining. A NC verification model based on Z-map was utilized to obtain chip load according to feed per tooth. This optimization method can regenerate a new NC program with respect to the commanded cutting conditions and the NC program that was generated from CAM system. The regenerated NC program has not only the same data of the ex-NC program but also the updated feed rate in every block. The new NC data can reduce the cutting time and produce precision products with almost even chip load to the feed per tooth. This method can also reduce tool chipping and make constant tool wear.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.801-805
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• 2000

This paper presents a new method of tool path optimization. A NC verification model based Z-map was utilized to obtain chip load in feed per tooth. This developed software can regenerate a NC program from cutting condition and the NC program that was generated in CAM. The regenerated NC program has not only all same data of the ex-NC program but also the new feed rates in every block. The new NC data can reduce the cutting time and manufacture precision dies with the same chip load in feed per tooth. This method can also prevent tool chipping and make constant tool wear. This paper considered the effects of acceleration and deceleration in feed rate change.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.2
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• pp.176-183
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• 2003

The paper presents a feature recognition and segmentation method for surface approximation in reverse engineering. Efficient digitizing plays an important role in constructing a computational surface model from a physical part-surface without its CAD model on hand. Depending on its measuring source (e.g., touch probe or structured light), each digitizing method has its own strengths and weaknesses in terms of speed and accuracy. The final goal of the research focuses on an integration of two different digitizing methods: measuring by the structured light and that by the touch probe. Gathering bulk of digitized points (j.e., cloud-of-points) by use of a laser scanning system, we construct a coarse surface model directly from the cloud-of-points, followed by the segmentation process where we utilize the z-map filleting & differencing to trace out feature boundary curves. The feature boundary curves and the approximate surface model could be inputs to further digitizing by a scanning touch probe. Finally, more accurate measuring points within the boundary curves can be obtained to construct a finer surface model.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.3-6
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• 2002

This paper presents the cutting simulation system for prediction and regulation of cutting force in CNC machining. The cutting simulation system includes geometric model, cutting force model, and off-line fred rate scheduling model. ME Z-map(Moving Edge node Z-map) is constructed for cutting configuration calculation. The cutting force models using cutting-condition-independent coefficients are developed for flat-end milling and ball-end milling. The off-line feed rate scheduling model is derived from the developed cutting force model. The scheduled feed rates are automatically added to a given set of NC code, which regulates the maximum resultant cutting force to the reference force preset by an operator. The cutting simulation system can be used as an effective tool for improvement of productivity in CNC machining.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.5
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• pp.58-64
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• 2000

This paper proposes a method for determining optimal EDM parameters based on discharge area from the physical model of a tool electrode. Main parameters, which affect the EDM performance, are peak value of currents, pulse-on time, and pulse-off time. Such parameters are closely dependent on the discharge area in EDM process. In this paper the discharge area is estimated from the CMM scanning data to the tool electrode. The method is very useful when any geometric information to the tool electrode is not provided from tool modeler or producer. The method consists of following four steps. First a triangulation mesh is constructed from the CMM data. Secondly, the z-map is modeled from the triangulated mesh. Thirdly, the discharge area is estimated from intersection between the z-map model and a z-height plane. Finally, the machining parameters are easily calculated by some known EDM equations to the discharge area. An example is introduced to show that the machining parameters are calculated from the CMM data to a tool electrode.