Journal Article10.1115/1.2830116
Milling process simulation : A generic solid modeller based paradigm
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TL;DR: In this paper, a solid modeller based 3-axis milling process simulation system is developed for ball end milling, where parts are described using a boundary representation solid model, and cutting edges are fitted with cubic Bezier curves.
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Abstract: A generic solid modeller based milling process simulation system is developed for 3-axis milling of complex parts. Parts are described using a boundary representation solid model, and cutting edges are fitted with cubic Bezier curves. For every completed tool path (i.e., one NC block), the tool swept volume is generated and intersected with the part, yielding the corresponding removed material volume. The tool cutting edges are then intersected with that volume to produce the tool-part immersion geometry. The mechanistic milling process model produces an accurate simulation of cutting forces, torque and power. Modelling of tool and tool holder dynamics is included. The system is based on a generic procedure for extracting geometric data required to accurately simulate milling of complex parts. Any tool shape can be represented, and extension to 4- and 5-axis machining is straightforward. Related processes such as turning and drilling can be modelled in a similar way. The capability of the system is demonstrated experimentally for ball end milling.
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Citations
Modeling of cutting geometry and forces for 5-axis sculptured surface machining
TL;DR: 5-Axis sculptured surface machining is simulated using discrete geometric models of the tool and workpiece to determine the tool contact area, and a discrete mechanistic model to estimate the cutting forces.
159
Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces
TL;DR: In this paper, a mechanistic modeling approach to predicting cutting forces for multi-axis ball end milling of free-form surfaces is developed for multiaxial machining.
129
Swept volumes: fundation, perspectives, and applications
TL;DR: A survey of swept volume concepts and methods consolidates and relates seemingly different terminology and methods and demonstrates the applicability of this seemingly simple formulation to the fields of solid modeling, robotics, manufacturing automation, and visualization.
123
Virtual cutting and optimization of three-axis milling processes
S. Doruk Merdol,Yusuf Altintas +1 more
TL;DR: In this paper, a generalized process simulation and optimization strategy is proposed to predict and improve the performance of three-axis milling operations, which can handle free-form part surfaces found in dies and molds.
110
Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models
TL;DR: In this paper, a feed rate process planner for complex sculptured end milling cuts is developed from mechanistic and geometric end-milling models. But the authors focus on improving the efficiency of CNC machining by automatic computer selection of feedrate for 3-axis sculptured surface machining.
95
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Martti Mäntylä
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TL;DR: This is a very reasonable book that should be read as discussed by the authors and the following may offer you the way to get this book: When the other people must walk around and go outside to get the book in the book store, you can just be by visiting this site.
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Ray casting for modeling solids
TL;DR: This paper presents ray casting as the methodological basis for a CAD/CAM solid modeling system and presents new methods, accompanied by sample pictures and CPU times, to meet the challenge.
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The prediction of cutting forces in end milling with application to cornering cuts
TL;DR: In this article, the authors present a mechanistic model for the force system in end milling, which is based on chip load, cut geometry, and the relationship between cutting forces and chip load.
504
Geometric Modeling for Swept Volume of Moving Solids
W.P. Wang,K.K. Wang +1 more
TL;DR: A novel method for modeling swept voume by computing a family of critical curves from a moving solid is presented, developed for real-time verification of NC tool paths using computer graphics.
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