Swept volume generation for the simulation of machining processes

To enhance the accuracy of five-axis milling processes, a simulation based NC-path optimization provides an efficient approach. The key to a reliable simulation of cutting processes is the accurate geometric modeling of engagement conditions and the resulting workpiece geometry. The article proposes a novel approach to calculate the cutter profile for modeling swept volume with respect to trajectory of the cutter. In terms of envelope theory, a swept volume is created as a NURBS surface representation. The proposed method is robust and the results can be applied to material removal simulations based on Boolean operation, as well as discrete methods.