Modeling of cutting geometry and forces for 5-axis sculptured surface machining |
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Authors: | BK Fussell [Author Vitae] RB Jerard [Author Vitae]Author Vitae] |
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Affiliation: | Department of Mechanical Engineering, University of New Hampshire, Durham, NH 03824, USA |
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Abstract: | 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. An extended Z-buffer model represents the workpiece, while a discrete axial slice model represents the cutting tool. Determination of the contact area for a given tool move requires a swept envelope (SWE) of the tool path. The SWE is used to find the intersections of the tool envelope with Z-buffer elements (ZDVs) representing the workpiece. A 3-axis approximation of the 5-axis tool movement is used to simplify the calculations while maintaining a desired level of accuracy. The intersection of the SWE with each ZDV yields segments which are used to find the contact area between the cutter and the workpiece for a given tool path. The contact area is subsequently used with the discrete force model to calculate the vector cutting force acting on the tool. |
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Keywords: | 5-Axis machining simulation Sculptured surface machining 5-Axis force estimation |
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